Bobcat 742b y 743b

7
4
2 Service
B Manual
7
4
3
B
6720772 (792) Printed in U.S.A. Melroe Company 1992
MAINTENANCE SAFETY
Instructions are necessary before operating or servicing machine. Read and
understand the Operation & Maintenance Manual, Operators Handbook and
WARNING signs (decals) on machine. Follow warnings and instructions in the manuals
when making repairs, adjustments or servicing. Check for correct function after
adjustments, repairs or service. Untrained operators and failure to follow
instructions can cause injury or death. W-2003-0903
Safety Alert Symbol: This symbol with a warning statement, means: Warning, be alert! Your safety is
involved! Carefully read the message that follows.
CORRECT CORRECT CORRECT
B-10731a B-12365 B-7469

Never service the Bobcat Skid- Use the correct procedure to lift or Cleaning and maintenance are
Steer Loader without instructions. lower operator cab. required daily.
WRONG WRONG WRONG
B-11799 B-15231 B-15280

Have good ventilation when Disconnecting or loosening any Never work on loader with lift
welding or grinding painted hydraulic tubeline, hose, fitting, arms up unless lift arms are held
parts. component or a part failure can by an approved lift arm support
Wear dust mask when grinding cause lift arms to drop. Do not go device. Replace if damaged.
painted parts. Toxic dust and gas under lift arms when raised Never modify equipment or add
can be produced. unless supported by an attachments not approved by
Avoid exhaust fume leaks which approved lift arm support device. Bobcat Company.
can kill without warning. Exhaust Replace it if damaged.
system must be tightly sealed.
WRONG WRONG WRONG
B-6590 B-6580 B-6589

B-16102 B-16102
Stop, cool and clean engine of Keep body, jewelry and clothing Lead-acid batteries produce
flammable materials before away from moving parts, flammable and explosive gases.
checking fluids. electrical contact, hot parts and Keep arcs, sparks, flames and
Never service or adjust loader exhaust. lighted tobacco away from
with the engine running unless Wear eye protection to guard batteries.
instructed to do so in the from battery acid, compressed Batteries contain acid which
manual. springs, fluids under pressure burns eyes or skin on contact.
Avoid contact with leaking and flying debris when engines Wear protective clothing. If acid
hydraulic fluid or diesel fuel are running or tools are used. contacts body, flush well with
under pressure. It can penetrate Use eye protection approved for water. For eye contact flush well
the skin or eyes. type of welding. and get immediate medical
Never fill fuel tank with engine Keep rear door closed except for attention.
running, while smoking or when service. Close and latch door
near open flame. before operating the loader.
Maintenance procedures which are given in the Operation & Maintenance Manual can be performed by the owner/
operator without any specific technical training. Maintenance procedures which are not in the Operation & Maintenance
Manual must be performed ONLY BY QUALIFIED BOBCAT SERVICE PERSONNEL. Always use genuine Bobcat
replacement parts. The Service Safety Training Course is available from your Bobcat dealer.
MSW01-0805
CONTENTS
PREVENTIVE
MAINTENANCE
FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii
SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . v
SERIAL NUMBER LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vii
DELIVERY REPORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vii
BOBCAT LOADER IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . viii HYDRAULIC
PREVENTIVE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 SYSTEM
HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
HYDROSTATIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
DRIVE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
MAIN FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 HYDROSTATIC
ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 SYSTEM
ENGINE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
DRIVE
SYSTEM
CALIFORNIA
PROPOSITION 65 WARNING MAIN
Diesel engine exhaust and some of its
constituents are known to the State of California FRAME
to cause cancer, birth defects and other
reproductive harm.
ELECTRICAL
SYSTEM
ENGINE
SERVICE
SPECIFICATIONS
742B, 743B Loader

Service Manual
FOREWORD
This manual is for the Bobcat loader mechanic. It provides necessary servicing and adjustment
procedures for the Bobcat loader and its component parts and systems. Refer to the Operation &
Maintenance Manual for operating instructions, starting procedure, daily checks, etc.
A general inspection of the following items must be made after the loader has had service or repair:
1. Check that the ROPS/FOPS 9. Enclosure door latches must

(Including sidescreens) is in open and close freely.
good condition and is not
modified.
2. Check that ROPS mounting 10. BobTach wedges and

hardware is tightened and is linkages must function
Melroe approved. correctly and be in good
condition.
3. The seat belt must be correctly 11. Safety treads must in good
installed, functional and in condition.
good condition.
4. The seat bar and pedal 12. Check for correct function of
interlocks must be correctly indicator lamps (Optional on
adjusted, clean and lubricated. some models).
5. Machine signs must be legible 13. Check hydraulic fluid level,

and in the correct location. engine oil level and fuel supply.
6. Steering levers and foot pedals 14. Inspect for fuel, oil or hydraulic
must return to neutral. fluid leaks.
7. Check for correct function of 15. Lubricate the loader.

the work lights.
8. The parking brake must 16. Check the condition of the

function correctly. battery and cables.
742B, 743B Loader

i Service Manual
17. Inspect the air cleaner for
damage or leaks. Check the
condition of the element.
18. Check the electrical charging

system.
19. Check tires for wear and

pressure.
20. Inspect for loose or broken

parts or connections.
21. Operate the loader and check

all functions.
22. Check for any field

modification not completed.
23. Check for correct function of

the Bobcat Interlock Control
System (BICS) before the
machine is returned to the
customer.
Recommend to the owner that all

necessary corrections be made
before the machine is returned to
service.
742B, 743B Loader

ii Service Manual
SAFETY INSTRUCTIONS
Instructions are necessary before operating or servicing machine. Read Operation & Maintenance Manual,
Handbook and signs (decals) on machine. Follow warnings and instructions in the manuals when making
repairs, adjustments or servicing. Check for correct function after adjustments, repairs or service. Failure
to follow instructions can cause injury or death.
W20030797
The following publications provide information on the safe use and maintenance of the loader and attachments:
The Delivery Report is used to assure that complete instructions have been given to the new owner and that the machine
is in safe operating condition.
The Operation & Maintenance Manual delivered with the loader gives operating information as well as routine
maintenance and service procedures. It is a part of the loader and must stay with the machine when it is sold. Replacement
Operation & Maintenance Manuals can be ordered from your Bobcat loader dealer.
The loader has machine signs (decals) which instruct on the safe operation and care. The signs and their locations are
shown in the Operation & Maintenance Manual. Replacement signs are available from your Bobcat loader dealer.
The loader has a plastic Operators Handbook fastened to the operator cab. Its brief instructions are convenient to the
operator. The handbook is available from your dealer in an English edition or one of the following languages: French,
German, Italian, Dutch & Spanish editions.
The EMI Safety Manual (available in Spanish) delivered with the loader gives general safety information.
The Service Manual and Parts Manual are available from your dealer for use by mechanics to do shoptype service and
repair work.
The SkidSteer Loader Operator Training Course is available through your local dealer. This course is intended to provide
rules and practices for correct operation of the Bobcat loader. The course is available in English and Spanish versions.
The Bobcat SkidSteer Loader Safety Video is available from your Bobcat Dealer.
Warnings on the machine and in the This notice identifies procedures

manuals are for your safety. Failure to which must be followed to avoid
obey warnings can cause injury or damage to the machine.
death. W20441285 I20190284
Safety Alert Symbol: This Safety Symbol is used for important safety messages. When you see this
symbol follow the safety message to avoid personal injury or death.
742B, 743B Loader

iii Service Manual
SAFETY INSTRUCTIONS (Contd)
Wear tight fitting clothing. Always wear safety glasses when maintaining or servicing loader. Safety glasses, hearing
protection or loader special applications kit are required for some work. See your dealer for Melroe Safety equipment.
Know where fire extinguisher and first aid kit are located and how to use them.
Do not use the Bobcat loader where exhaust, arcs, sparks or hot components can contact flammable material, explosive
dust or gases.
The engine compartment and engine cooling system must be inspected every day and cleaned if necessary to prevent
fire hazard and overheating.
Check all electrical wiring and connections for damage. Keep the battery terminals clean and tight. Repair or replace any
damaged part.
Check fuel and hydraulic tubes, hoses and fittings for damage and leakage. Never use open flame or bare skin to check
for leaks. Tighten or replace any parts that show leakage. Always clean fluid spills. Do not use gasoline or diesel fuel for
cleaning parts. Use commercial nonflammable solvents.
Follow any environmental safety regulations when disposing of used fluids such as engine oil, grease or antifreeze.
Do not use ether or starting fluids on this engine. It has a glow plug. These starting aids can cause explosion and injure
you or bystanders.
Always clean the loader and disconnect the battery before doing any welding. Cover rubber hoses, battery and all other
flammable parts. Keep a fire extinguisher near the loader when welding. Have good ventilation when grinding or welding
painted parts. Wear dust mask when grinding painted parts. Toxic dust or gas can be produced.
Stop the engine and let it cool before adding fuel. No smoking!
Use the procedure in the Operation & Maintenance or Service Manuals for connecting the battery.
A fire extinguisher is available from your local dealer. The fire extinguisher can be installed in the location shown [A].
P03705
742B, 743B Loader

iv Service Manual
SERIAL NUMBER LOCATIONS
Always use the serial number of the loader when
A
requesting service information or when ordering parts.
Early or later models (identification made by serial
number) may use different parts, or it may be necessary
to use a different procedure in doing a specific service
operation.
LOADER SERIAL NUMBER
The loader serial number plate is located on the inside of
the left upright, above the grill [A].
Explanation of loader Serial Number:
XXXX XXXXX P00144
Module 2. Production
Sequence (Series) B
Module 1. Model/Engine
Version
The four digit Model/Engine Combination module number
identifies the model number and engine combination.
This number (in parenthesis beside the model number) is
used in the Service Manual to more easily identify the
standard, optional and field accessory equipment
included or available for each specific model.
The five digit Production Sequence Number identifies the
order which the loader is produced.
ENGINE SERIAL NUMBER (743B) P00208
The serial number is located at the fuel injection pump

side on the engine block [B].
C
ENGINE SERIAL NUMBER (742B)
The serial number is located at top left surface of the

engine block [C].
B09644
DELIVERY REPORT
The Delivery Report must be filled out by the dealer and

D
signed by the owner or operator when the Bobcat loader
is delivered. An explanation of the form must be given to
the owner. Make sure it is filled out completely [D].
742B, 743B Loader

v Service Manual
BOBCAT SKID STEER LOADER IDENTIFICATION
742B(S/N509418001&Above),743B(S/N509318001&Above)ServiceManual#6720772ContentsSection
FRONT LIGHTS
(OPT.)
SEAT BAR
GRAB
HANDLES OPERATOR
STEERING SEAT
LEVER
SEAT BELT
QUICK COUPLERS
TILT CYLINDER
BUCKET SAFETY TREAD

BUCKET STEPS
SEAT BAR
OPERATOR CAB
(ROPS & FOPS)
REAR LIGHT
LIFT ARM SUPPORT DEVICE
(OPT.)
UPRIGHTS
LIFT ARM
LIFT CYLINDER
GRILL
REAR DOOR
*TIRES B07377
C02878
* TIRES Flotation tires are shown. THE Bobcat loader is basedequipped with standard tires.
BUCKET Several different buckets and other attachments are available for the Bobcat loader.
ROPS, FOPS RollOver Protective Structure, Falling Object Protective Structure, per SE J1040 and
SAE J1043. The Bobcat loader is baseequipped with a standard operator cab as shown.
742B, 743B Loader

vi Service Manual
PREVENTIVE MAINTENANCE
PREVENTIVE
Page MAINTENANCE
Number
AIR CLEANER SERVICE (743B)
Replacement Of The Filter Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Replacement Of The Filter Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
ALTERNATOR BELT ADJUSTMENT (743B)

Adjusting The Alternator Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Adjusting The Alternator Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
ENGINE COOLING SYSTEM (743B)

Cleaning The Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
Coolant Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
Removing Coolant From The Cooling System . . . . . . . . . . . . . . . . . . . . . 116

Cleaning The Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
Coolant Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
Removing Coolant From The Cooling System . . . . . . . . . . . . . . . . . . . . . 118
ENGINE LUBRICATION SYSTEM (743B)

Checking Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Replacing Oil And Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113

Checking Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Replacement Of The Oil And Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
FINAL DRIVE TRANSMISSION (Chaincase)
Checking And Adding Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
FUEL SYSTEM (743B)

Filling The Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Fuel Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Removing Air From The Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
FUEL SYSTEM (742B)

Filling The Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Fuel Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
GOVERNOR (742B)
Governor Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Governor Belt Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Governor Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
HYDRAULIC/HYDROSTATIC SYSTEM
Checking And Adding Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
Hydraulic/Hydrostatic Filter Replacement . . . . . . . . . . . . . . . . . . . . . . . . . 124
Removing The Hydraulic Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
742B, 743B Loader

Service Manual
PREVENTIVE MAINTENANCE (Contd)
Page
Number
To Disengage Lift Arm Support Device . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
To Engage Lift Arm Support Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
LIFTING AND BLOCKING THE LOADER

Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
LUBRICATING THE BOBCAT LOADER

Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
OPERATOR CAB
Lowering The Operator Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Raising The Operator Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
PARKING THE LOADER
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
REMOTE START SWITCH

Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
SEAT BAR RESTRAINT SYSTEM

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Seat Bar Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Seat Bar Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
SERVICE SCHEDULE
Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
SPARK ARRESTOR MUFFLER

Cleaning Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
TIRE MAINTENANCE
Tire Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
Tire Rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
Wheel Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
TRANSPORTING THE BOBCAT LOADER
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
USING A BOOSTER BATTERY (Jump Starting)

Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
UJOINT LUBRICATION
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
742B, 743B Loader

10 Service Manual
SERVICE SCHEDULE
Maintenance work must be done at regular intervals. Failure to do so will result in excessive wear and early failures. The
service schedule is a guide for correct maintenance of the Bobcat loader.
Instructions are necessary before operating or servicing machine. Read

Operation & Maintenance Manual, Handbook and signs (decals) on
machine. Follow warnings and instructions in the manuals when making
repairs, adjustments or servicing. Check for correct function after
adjustments, repairs or service. Failure to follow instructions can cause
injury or death.
W20030797
SERVICE SCHEDULE HOURS
ITEM SERVICE REQUIRED 810 50 100 250 500 1000

Engine Oil Check the oil level & add oil as needed.
Engine Air Cleaner Replace the outer filter element only when the read ring shows
in the indicator window. Check for leaks & damaged
components.
Engine Cooling System Clean debris from shrouds & grill. Check coolant level in the
recovery tank & add as needed.
Tires Check for damaged tires & correct air pressure.
Seat Belt, Seat Bar Check the condition of seat belt. Check the seat bar & pedal
& Pedal Interlocks. interlocks for correct operation.
Safety Signs & Check for damaged signs (decals) & safety treads. Replace
Safety Tread any signs or safety treads that are damaged or worn.
Lift Arm, Cyl., BobTach, Add grease to the fittings until extra grease shows.
Pivot Pin
Fuel Filter (743B) Remove water from tilter.
Operator Cab Check the fastening bolts, washers & nuts. Check the
condition of the cab.
Wheel Nuts Check for loose wheel nuts. Tighten to correct torque if loose.
Battery Check the electorlite level. Check battery cables for corrosion.
Check that the battery cables are tight. Check covers.
Hydraulic Fluid, Tubelines Check the fluid level & add as needed. Check for damage &
& Hoses leaks & replace as needed.
Alternator Drive Belt Check the tension & adjust as needed.
Chaincase Check the fluid level & add as needed.
Controls & Brake Check operation & adjust as needed.
Engine Oil & Filter Replace the oil & the engine oil filter.
Spark Arrestor Muffler Remove the plug & clean the spark chamber.
Governor Oil Level (742B) Check level, if low, add oil.
Governor Shaft (742B) Grease or oil the shaft.
Seat Bar Grease pivot as needed.
Steering Shaft Pivots Grease two fittings. Add oil to steering shaft.
Hyd./Hydro. Filters Replace filter elements.
UJoint Grease three fittings with correct grease.
Fuel Filter Replace the filter element.
Hyd. Reservoir Breather Replace breather cap.
Cap
Chaincase Replace the fluid.
Hydraulic Reservoir Replace the hydraulic fluid.
Case Drain Filter Replace the filter.
Check wheel nut torque every 8 hours for the first 24 hours.
Also replace hydrostatic filter element when the transmission warning light stays on for five minutes after the
hydrostatic fluid is at operating temperature.
Or every 12 months.
Replace case drain filter in the event of any Hydraulic/Hydrostatic System failure.
742B, 743B Loader
Revised Sept. 93 11 Service Manual
A
Instructions are necessary before operating or

servicing machine. Read Operation &
Maintenance Manual, Handbook and signs
(decals) on machine. Follow warnings and
instructions in the manuals when making
repairs, adjustments or servicing. Check for
correct function after adjustments, repairs or
service. Failure to follow instructions can
cause injury or death [A].
W20030797
LIFTING AND BLOCKING THE LOADER

Procedure
Always park the loader on a level surface. B07023
Put jackstands under the front axles and rear

corners of the frame before running the engine
for service. Failure to use jackstands can allow
the machine to fall or move and cause injury or
death.
W20170286
B
Put floor jack under the rear of the loader [B].
Lift the rear of the loader and install jackstands [B].
B09331
Put the floor jack under the front the loader [C].
Lift the front of the loader and put jackstands [C].
C
NOTE: Make sure the jackstands do not touch the

tires.
B09332
742B, 743B Loader

12 Service Manual
PARKING THE BOBCAT LOADER
Procedure
A
Stop the Bobcat loader on level ground.
Lower the lift arms fully and put the edge of the bucket on
the ground.
Pull the throttle all the way backward. Turn the key switch
to the OFF position.
SUPPORT B02668
AVOID INJURY OR DEATH

Before you leave the operators seat: B
Lower the lift arms, put the attachment flat on
the ground.
Stop the engine.
Engage the parking brake.
Raise seat bar, move pedals until both lock.
W20451086
Engage the parking brake.

Lift the seat bar and make sure the foot pedals are in the C02563 B07384
locked position.
Unbuckle the seat belt. Remove the key from the switch
to prevent operation of the loader by unauthorized
personnel.
TRANSPORTING THE BOBCAT LOADER
Adequately designed ramps of sufficient

strength are needed to support the weight of
the machine when loading onto a transport
vehicle. Wood ramps can break and cause
personal injury.
W20580494
A loader with an empty bucket or no attachment must be B07383

loaded backward onto the transport vehicle [A].
The rear of the trailer must be blocked or supported [A]
when loading or unloading the loader to prevent the front
end of the trailer from raising up.
Use the following procedure to fasten the Bobcat loader
to the transport vehicle to prevent the loader from moving
during sudden stops or when going up and down slopes
[B].
Lower the bucket or attachment to the floor. Stop the
engine. Engage the parking brake. Install chains at the
front and rear of the loader as shown in figure [B].
742B, 743B Loader

13 Service Manual
A
Never work on a machine with the lift arms up

unless the lift arms are secured by a lift arm
support device. Failure to use an approved lift
arm support device can allow the lift arms or
attachment to fall and cause injury or death.
W20590991
P00147
To Engage Lift Arm Support Device
Maintenance and service work can be done with lift arms
lowered. If the lift arms are raised, use the following
B
procedure:
Put jackstands under the rear corners of the loader.
Disconnect the spring from the lift arm support device
retaining pin, hold onto the support device and remove
the retaining pin [A].
Lower the lift arm support device on top of the lift cylinder.
Hook the free end of the spring to the lift arm support
device so there will be no interference with the support
device engagement [B].
With the operator in the seat, seat belt fastened and seat
bar lowered, start the engine. P00192
Raise the lift arms, until the lift arm support device is on
the lift cylinder rod [C]. C
Lower the lift arms slowly until the support device is held
between the lift arm and the lift cylinder. Stop the engine.
Raise the seat bar and move pedals until both pedals
lock.
Install pin into the rear of the lift arm support device below
the cylinder rod.
To Disengage Lift Arm Support Device

Remove the pin from the lift arm support device. P00193
Connect the spring from the lift arm support device to the
bracket below the lift arms [D].
D
With the operator in the seat, seat belt fastened and seat
bar lowered, start the engine.
Raise the lift arms a small amount and the spring will lift
the support device off the lift cylinder rod. Lower the lift
arms. Stop the engine.
Raise the seat bar and move pedals until both pedals
lock.
Disconnect the spring from the bracket.
Raise the support device into storage position and insert
pin through lift arm support device and bracket [A].
Connect spring to pin. P00148
742B, 743B Loader

14 Service Manual
OPERATOR CAB
Nut
The Bobcat loader has an operator cab (ROPS and
A Plate
FOPS) as standard equipment to protect the operator Bushing

from rollover and falling objects. Check with your dealer Washer Washer
if the operator cab has been damaged. Bolt
MC01181
Never modify operator cab by welding,

grinding, drilling holes or adding attachments
unless instructed to do so by Melroe P00150
Company. Changes to the cab can cause loss
of operator protection from rollover and falling
objects, and result in injury or death.
W20691285 B
Raising The Operator Cab
Stop the loader on a level surface. Lower the lift arms. If
the lift arms must be up while raising the operator cab,
install the lift arm support device. (See Page 14.)
P00151 P00152
Before the cab or the lift arms are raised for
service, jackstands must be put under the rear
corners of the frame. Failure to use jackstands
can allow the machine to tip backward causing C
injury or death.
W20140895
Loosen the nut (both sides) at the corner of the operator

cab [A].
Remove the nut and plate (both sides) [B].

Remove the bolt and washer (both sides) [B].
Lift on the grab handle and bottom of the operator cab
slowly until the cab latching mechanism engages and the
P00153
cab is all the way up [C].
D
Lowering The Operator Cab
Pull down on the bottom of the operator cab until it stops
at the latching mechanism. Release the latching
mechanism and pull the cab all the way down [D].
Install bolt and washer from underneath the fender.
Install the plate and nut [B].
Tighten the nuts to 4050 ft.lbs. (5468 Nm) torque [A].
P00154
742B, 743B Loader

Revised May 96 15 Service Manual
SEAT BAR RESTRAINT SYSTEM
Description
A
The seat bar restraint system has a pivoting seat bar with
arm rests and has spring loaded interlocks for the lift and
tilt control pedals. The operator controls the use of the Clean &
seat bar. The seat bar in the down position helps to keep Lubricate
the operator in the seat. The interlocks require the
operator to lower the seat bar in order to operate the foot
pedal controls. When the seat bar is up, the lift and tilt
pedals are locked when returned to the neutral position.
P00155
AVOID INJURY OR DEATH B

The seat bar system must lock the lift and tilt
control pedals in neutral when the seat bar is
up. Service the system if pedals do not lock
correctly. W21051285
Seat Bar Inspection

Clean
Sit in the seat and fasten the seat belt. Engage the
parking brake. Pull the seat bar all the way down. Start the
engine. Operate each foot pedal to check both the lift and
tilt functions. Raise the lift arms until the bucket is about
2 feet (600 mm) off the ground.
P00156
Raise the seat bar. Try to move each foot pedal. Pedals
must be firmly locked in neutral position. There must be
no motion of the lift arms or tilt (bucket) when the pedals
are pushed.
Pull the seat bar down, lower the lift arms. Operate the lift
pedals. While the lift arms are going up, raise the seat bar
and the lift arms should stop.
Lower the seat bar, lower the lift arms and place the
bucket flat on the ground. Stop the engine. Raise the seat
bar and operate the foot pedals to be sure that the pedals
are firmly locked in the neutral position. Unbuckle the seat
belt.
Seat Bar Maintenance

Clean any debris or dirt from the moving parts [A] & [B].
Inspect the linkage bolts and nuts for tightness. The
correct torque is 2528 ft.lbs. (3438 Nm).
Use a general purpose grease to lubricate the seat bar
pivot points at each side of the cab [A]. If the seat bar
system does not function correctly, check for free
movement of each linkage part. Check for excessive
wear. Adjust pedal control linkage. Replace parts that are
worn or damaged. Use only genuine Melroe replacement
parts.
742B, 743B Loader

Replacement Of The Filter Element
A
See the SERVICE SCHEDULE Page 11 for the interval
to service the air cleaner system.
Check the air intake hose for damage. Check the air P00162
cleaner housing for damage. Check to make sure all
connections are tight.
Replace the large (outer) filter element only when the red
ring shows in the window of the condition indicator (Item
1) [A]. 1
NOTE: Push the button on the condition indicator

(see Inset) and start the engine. If the red ring P00161
does not show, do not replace the filter
element [A].
B
Service the air cleaner as follows:
Remove the dust cover wing nut [B].
P00212
Remove the dust cover [C].

C
P00213
Remove the wing nut at the large air filter element [D].
D
P00214
742B, 743B Loader

17 Service Manual
AIR CLEANER SERVICE (743B) (Contd)
A
Replacement Of The Filter Element (Contd)
Remove the large filter element.
NOTE: Make sure all sealing surfaces are free of dirt
and debris.
Install the new filter element and tighten the wing nut.
Install the dust cover and tighten the wing nut.
P00215
Only replace the inner filter element under the following

conditions [B]. B
Replace the inner filter element every third time the outer
filter is replaced.
Replace the inner filter element when the red ring still
shows in the condition indicator window after the outer
filter is replaced.
P00216
Record the operating hours of the loader on the decal

(Item 1) [C] inside the rear door. C
P00169
742B, 743B Loader

18 Service Manual
A
Replacement Of The Filter Element
to service the air cleaner system
Check the air intake hose for damage. Check the air P0705
P00705
P0705
cleaner housing for damage. Check to make sure all
connections are tight.
Service the air cleaner as follows:
NOTE: Before replacing the filter element, push the
button on the condition indicator (Inset) and,
start the engine [A] . If the red ring does not
show, do not replace the filter element. P00707
Loosen the clamp on the dust cup [A].

B
Remove the dust cup [B].
P00708
Remove the wing nut [C].

C
P00703
Remove the element [D].

Check the air cleaner housing for holes or corrosion. D
Install the new filter element.
Install the dust cup so the arrow on the cup is up. Tighten
the clamp.
All the hoses and clamps must be tight.
Push the button on the condition indicator to remove the
red ring.
P00712
742B, 743B Loader

19 Service Manual
FUEL SYSTEM (743B)
A
Fuel Specifications
Use only clean, high quality fuel. Use Grade No. 2 fuel
above 40F. (4C.). Use Grade No. 1 fuel at temperatures
below 40F. (4C.).
Filling The Fuel Tank
Stop and cool the engine before adding fuel. P00196

NO SMOKING! Failure to obey warnings can
cause an explosion or fire.
W20630887
B WRONG
Remove the fuel fill cap [A].
Use a clean, approved safety container to add fuel of the
correct specifications. Add fuel only in an area that has
free movement of air and no open flames or sparks. NO
SMOKING [B].
Install and tighten the fuel fill cap [A].
Fuel Filter
B06586
Always clean up spilled fuel or oil. Keep heat, C

flames, sparks or lighted tobacco away from
fuel and oil. Failure to use care around
combustibles can cause explosion or fire
which can result in injury or death.
W21031285
See the SERVICE SCHEDULE Page 11 for the service

interval when to remove the water from the fuel filter.
Turn the fuel shutoff valve clockwise to shutoff the fuel
supply [C].
Loosen the drain at the bottom of the filter element (Item
1) [D] to drain the water from the filter [D].
P00194
Open the shutoff valve [C].
interval when to replace the fuel filter.
D
2
Clean the area around the fuel filter. Close the shutoff
valve [C].
Use a wrench to loosen the fuel filter bolt (Item 2) [D].
Remove the water trap and fuel filter (Item 3) [D]. 3
Replace the seals as needed.
Install the new filter element and water trap.
Tighten the fuel filter bolt.
1
Open the shutoff valve [C]. P00170
742B, 743B Loader

110 Service Manual
FUEL SYSTEM (743B) (Contd)
A
Removing Air From The Fuel System
After replacing the fuel filter element or when the fuel tank
has run out of fuel, the air must be removed from the fuel 1
system before starting the engine.
Open the rear door. The engine must be cool.
Open the vent plug (Item 1) [A]. 2
Operate the hand pump (Item 2) [A] until fuel flows from
the vent plug with no air bubbles.
Tighten the vent plug.
P00171
Operate the hand pump until it feels solid.
B
Move the engine speed control to minimum RPM. Open
the valve (Item 1) [B] and squeeze the hand pump several
times.
Start the engine. When the engine runs smoothly, close 1
the valve (Item 1) [B].
P00217
Always clean up spilled fuel or oil. Keep heat,
W21031285
742B, 743B Loader

111 Service Manual
FUEL SYSTEM (742B)
A
Fuel Specifications
Use leaded or unleaded gasoline in the engine.
Stop and cool the engine before adding fuel.

NO SMOKING! Failure to obey warnings can
cause an explosion or fire.
W20630887 P00704
Filling The Fuel Tank

Remove the filler cap [A].
B WRONG
Use a clean, approved safety container to add fuel.

The key switch must be in the OFF position and the
engine cool.
Add fuel only in an area that has free movement of air and
no open flames or sparks. NO SMOKING [B].
After the fuel has been added install the filler cap and
tighten.
B06586
Fuel Filter
C
to service the fuel filter.
Close the valve on the fuel line (Item 1) [C].
Remove the filter element. Install the new filter element.
All connections must be tight.
Open the valve at the fuel tank [C]. 1
P00713

W21031285
742B, 743B Loader

112 Service Manual
ENGINE LUBRICATION SYSTEM 743B)
Checking Engine Oil
A
Check the oil level every day.
Stop the engine and remove the dipstick [A].
Keep the oil level between the marks on the dipstick.
Use a good quality motor oil that meets API Service
Classification of CC, CD or CE. (See Oil Chart.)
Replacing Oil And Filter
interval for replacing the engine oil and filter. P00180
Use the following procedure to replace the oil and filter:
Run the engine until it is at operating temperature. Stop

B
the engine.
Open the rear door and remove the cap from the end of
the hose and drain the oil into a container [B].
Remove the filter [C].
Clean the filter housing surface. Put clean oil on the
gasket of the new filter install the filter and tighten hand
tight.
Remove the oil filler cap [D].
Use a good quality motor oil that meets API Service P00176
Classification of CC, CD or CE. (See Oil Chart.)
RECOMMENDED SAE VISCOSITY NUMBER

(LUBRICATION OILS FOR ENGINE CRANKCASE)
C
C34 29 23 18 13 7 1 +4 +10 +15 +21 +27 +32 +38 +43 +49 +54 +60
SAE 40 or 20W50
SAE 10W30
SAE 15W40
SAE 5W30
SAE 30W
SAE 20W20
P00209
SAE 10W
F30 20 10 0 +10 +20 +30
TEMPERATURE RANGE ANTICIPATED BEFORE

+40 +50 +60 +70 +80 +90 +100 +110 +120 +130 +140
D
NEXT OIL CHANGE
(DIESEL: USE API CLASSIFICATION CC, CD or CE)
P00177
742B, 743B Loader

ENGINE LUBRICATION SYSTEM (743B) (Contd)
A
Replacing Oil And Filter (Contd)
Fill to capacity [A]. (See SPECIFICATION Section 8.)
Start the engine and let it run for about 5 minutes. Check
for leaks at the filter. Check the oil level. Add oil until the
level is at the FULL mark on the dipstick. Install the oil filler
cap
NOTE: DO NOT overfill the crankcase.
P00203
Record the operating hours of the loader on the decal

inside the rear door [B]. B

W21031285
P00169
742B, 743B Loader

114 Service Manual
Checking Engine Oil
A
Check the oil level every day.
Stop the engine and remove the dipstick [A].
Keep the oil level between the marks on the dipstick.
Use a good quality motor oil that meets API Service
Classification of SF or SG. (See Oil Chart.)

C34 29 23 18 13 7 1 +4 +10 +15 +21 +27 +32 +38 +43 +49 +54 +60
P00720
SAE 40 or 20W50
SAE 10W30
B
SAE 15W40
SAE 5W30
SAE 30W
SAE 20W20
SAE 10W
F30 20 10 0 +10 +20 +30 +40 +50 +60 +70 +80 +90 +100 +110 +120 +130 +140

NEXT OIL CHANGE
(GASOLINE: USE API CLASSIFICATION SF or SG) P00706
Replacement Of Oil And Filter
See the SERVICE SCHEDULE Page 11 for the service C
interval for replacing the engine oil.
Use the following procedure to replace the engine oil and
filter:
Run the engine until it is at operating temperature. Stop the
engine.
Open the rear door.
Remove the drain plug and drain oil into a container [B].
Remove the oil filter [C].

P00722
Clean the filter housing surface. Put clean oil on the gasket
of the new filter. Install the filter and tighten hand tight.
Install the oil plug. Remove the filler cap on the rocker arm
D
cover. Put 4 quarts (4L) of oil in the engine. (See the Oil
Chart.)
Start the engine and let it run for about 5 minutes. Stop the
engine. Check for leaks and check the oil level. Add oil as
needed if it is not at the top mark on the dipstick.
Record the operating hours on the decal inside the rear

door [D].
P00169
742B, 743B Loader

115 Service Manual
Coolant Level
A
Check the cooling system every day to prevent
overheating, loss of performance or engine damage.
Open the rear door.
The coolant recovery tank (Item 1) [A] must be at the 1
FULL COLD mark when engine is cool.
Add premixed coolant, 50 % water and 50% antifreeze
to the recovery tank if the coolant level is low.
P00178
B
Wear safety glasses to prevent eye injury when
any of the following conditions exist:
When fluids are under pressure.
Flying debris or loose material is present.
Engine is running.
Tools are being used.
W20191285
Cleaning The Cooling System

P00187
Open the rear door.
Remove the access panels at the blower housing [B].
C
Remove the rear grill. (See MAIN FRAME Section 5.)
Use air pressure or water pressure to remove the debris

in the area of the radiator and oil cooler [C].
If debris is a problem, check with your dealer about the
special debris screens.
P00146
Removing Coolant From The Cooling System

D
Remove the radiator cap [D].
P00145
742B, 743B Loader

116 Service Manual
ENGINE COOLING SYSTEM (743B) (Contd)
A
(Contd)
Connect a hose to the coolant drain valve (Item 1) [A] or
use a funnel to keep coolant from getting into the engine
compartment. Open the valve and drain coolant into a
container.
1
When all the coolant is removed close the valve.
Fill the radiator with premixed coolant and install the
radiator cap.
P00174
Fill the coolant recover tank 1/3 full with premixed

coolant [B].
B
Check the radiator cap for correct pressure rating or
overheating can result.
Check for leaks in the cooling system. Check for worn or
damaged hoses, clamps or radiator. Check for loose or
worn water pump belt.
Replace damaged parts immediately to prevent leaks and
overheating.
Install the rear grill.
P00178
742B, 743B Loader

117 Service Manual
Coolant Level
A
Check the cooling system every day to prevent
overheating, loss of performance or engine damage.
The coolant recovery tank (Item 1) [A] must be at the
FULL COLD mark when engine is cool.
1
Fill with premixed coolant, 50 % water and 50%
antifreeze.
P00724
Do not remove radiator cap when the engine is

hot. You can be seriously burned.
B
W20701285 1
Cleaning The Cooling System

Open the rear door.
Remove the access panels at the blower housing.
Use air pressure or water pressure to remove the debris
in the area of the radiator and oil cooler. P00145
If debris is a problem, check with your dealer about the
special debris screens.
C
Check the radiator cap (Item 1) [B] for correct pressure
rating or overheating can result.
Check for leaks in the cooling system. Check for worn or
damaged hoses, clamps or radiator. Check for loose or
worn water pump belt.
Replace damaged parts immediately to prevent leaks and
overheating.

To remove the coolant from the engine and radiator, use
B09901
the following procedure:
D
Remove the radiator cap (Item 1) [B].
Remove the radiator hose [C].
Drain the coolant into a container [D].
Fill the radiator with premixed coolant, 50% water and
50% antifreeze.
Fill the coolant recovery tank so it is 1/3 full.
B09960
742B, 743B Loader

118 Service Manual
A 2
Adjusting The Alternator Belt
Stop the engine.
1
Loosen the mounting bolt (Item 1) [A] and adjustment bolt
(Item 2) [A]. Move the alternator to set the belt tension at
5/16 inch (8 mm) movement between pulleys with 15
pounds (67 N) of force. Tighten the adjustment bolt and
mounting bolt.
5/16
(8 mm)
P00204
742B, 743B Loader

119 Service Manual
A
Adjusting The Alternator Belt
To adjust the belt tension, use the following procedure:
Stop the engine.
Remove the belt shield [A].
P09640
Loosen the bolts that mount the alternator [B]. B
P09639
Move the alternator until the belt tension permits 1/4 inch
movement at the middle of the belt with 20 lbs. (9 kg) of
force. Tighten the bolts [B].
C
B09641
742B, 743B Loader

120 Service Manual
GOVERNOR (742B)
Governor Belt Adjustment
A
To adjust the belt tension, use the following procedure:
Stop the engine.
Remove the belt shield [A].
P00732
Loosen the bolts that mount the governor [B].

B
P00735
Move the governor until the belt tension permits 1/4 inch
(6,3 mm) movement at the middle of the belt with 20 lbs. C
(9 kg) of force. Tighten the bolts [C].
Governor Adjustment
1
To adjust the governor linkage, use the following
procedure:
Stop the engine.
Loosen the screws (Item 1) [C] on the governor arm.
Hold the governor arm in the closed position. Tighten the
screws. P02046
Install the belt shield before starting the engine.

Governor Oil Level D 2
interval for checking the governor oil level. Use the
following procedure:
Remove the check plug (Item 1) [D] at the rear of the
governor.
If oil flows out the hole, the level is adequate. 1
If no oil flows out the hole, remove the fill plug (Item 2) [D]
at the top of the governor and add SAE 10W30 or
10W40 until oil flows from the check plug hole. Install the
plug and tighten. P00745
742B, 743B Loader

Revised July 96 121 Service Manual
USING A BOOSTER BATTERY (Jump Starting) 743B
Procedure
A
Batteries contain acid which burns eyes and

skin on contact. Wear goggles, protective
clothing and rubber gloves to keep acid off
body.
In case of acid contact, wash immediately with
P00202
water. In case of eye contact get prompt medical
attention and wash eye with clean, cool water
for at least 15 minutes. 742B
If electrolyte is taken internally drink large
B
quantities of water or milk! DO NOT induce
vomiting. Get prompt medical attention.
W20651296
If it is necessary to use an extra battery to start the engine, B09645

BE CAREFUL There must be one person in the
operators seat and one person to connect and
disconnect the battery cables.
The ignition must be in the OFF position. The booster
battery to be used must be 12 volt.
Connect the end of the first cable to the positive terminal
(+) of the booster battery. Connect the other end of the
same cable to the loader battery positive (+) terminal [A]
or [B].
Connect the end of the second cable to the negative B09646
terminal () of the booster battery. Connect the other end
of second cable to the engine and/or starter solenoid [A]
or [B].
Keep the cables away from moving parts. Start the
engine. (Also See Preheat Condition in the Operation &
Maintenance Manual.)
Remove the cable from the loader battery.
Close the rear door.
Keep arcs, sparks, flames and lighted tobacco

away from batteries. When jumping from
booster battery make final connection
(negative) at engine frame.
Do not jump start or charge a frozen or damaged
battery. Warm battery to 60F. (16C.) before
connecting to a charger. Unplug charger before
connecting or disconnecting cables to battery.
Never lean over battery while boosting, testing
or charging.
Battery gas can explode and cause serious
injury.
W20661296
742B, 743B Loader

122 Service Manual
HYDRAULIC/HYDROSTATIC SYSTEM
A
Checking And Adding Fluid 1
Use only recommended fluid in the hydraulic/hydrostatic
system. (See SPECIFICATIONS Section 8 for the correct
fluid.)
To check the fluid in the reservoir, use the following
procedure:
Put the loader on a level surface. Lower the lift arms and
lay the attachment flat on the ground. Stop the engine.
Hydraulic fluid must show in the sight glass (Item 1) [A].
P00163
If the fluid is not seen in the sight glass, remove the filler
cap from the reservoir [B]. B
P00165
Add fluid to the reservoir until it shows in the sight glass

[C]. Replace the filler cap. C
P00166
742B, 743B Loader

123 Service Manual
HYDRAULIC/HYDROSTATIC SYSTEM (Contd) 743B
A
Hydraulic/Hydrostatic Filter Replacement
See the SERVICE SCHEDULE Page 11 for the correct
service interval.
Stop the engine. Open the rear door.
Clean the area around the filter housing.
Remove the filter element (Item 1) [A] or [B].
1
Clean the surface of the filter housing head where the

filter element seal contacts the filter housing.
Lubricate the rubber gasket with grease. P00181
Install the filter element and hand tighten [A] or [B].

742B
Operate the loader and check for leaks at the filter.
B
Check fluid level in the reservoir and add as needed.
Removing The Hydraulic Fluid

See the SERVICE SCHEDULE Page 11 for the service 1
interval to replace the fluid. The fluid must also be
replaced if it becomes contaminated and after any major
repairs.
P00726
Remove the filler cap from the reservoir [C].

C
Remove the screen from the fill pipe [D].
Remove fluid from the hydraulic reservoir with a hydraulic
transfer pump or a hand operated suction pump.
Wash the screen in clean solvent. Install the screen in the
fill pipe.
Remove the filter element and install a new filter element.
Add hydraulic/hydrostatic fluid to the reservoir. (See
SPECIFICATIONS Section 8 for the correct fluid.) DO P00165
NOT fill above the sight glass.
Operate the loader. Stop the engine and check the fluid
level. Add as needed. D

W21031285
P00164
742B, 743B Loader

124 Service Manual
SPARK ARRESTOR MUFFLER
742B(S/N509418001&Above),743B(S/N509318001&Above)ServiceManual#6720772PreventiveMaintenanceSectionPart1of2
A
Cleaning Procedure
See the SERVICE SCHEDULE Page 11 for correct
service interval. Do not operate the loader with a defective
exhaust system.
This loader is factory equipped with a U.S.D.A.

Forestry Service approved spark arrestor P00188
muffler. It is necessary to do maintenance on
this spark arrestor muffler to keep it in working
condition. The spark arrestor muffler must be
serviced by dumping the spark chamber every
100 hours of operation.
If this machine is operated on flammable forest,
brush or grass covered land, it must be
equipped with a spark arrestor attached to the
exhaust system and maintained in working
order. Failure to do so will be in violation of
California State Law, Section 4442 PRC.
Stop engine an allow the muffler to cool before
Make reference to local laws and regulations for cleaning the spark chamber. Wear safety
spark arrestor requirements. goggles. Failure to obey can cause serious
I20220595 injury.
W20111285
Stop the engine. Open the rear door. When an engine is running in an enclosed area,
fresh air must be added to avoid concentration
Remove the plug at the bottom of the muffler (Item 1) [A]. of exhaust fumes. If the engine is stationary,
vent the exhaust outside. Exhaust fumes
contain odorless, invisible gases which can kill
without warning.
W20501285
Never use machine in atmosphere with

explosive dust or gases or where exhaust can
contact flammable material. Failure to obey
warnings can cause injury or death.
W20681285
Start the engine.

Wearing safety goggles, have a second person hold a
block of wood over the outlet of the muffler (with the
engine running) for about 10 seconds.
Stop the engine and install the plug. Close the rear door.
742B, 743B Loader

125 Service Manual
TIRE MAINTENANCE
A
Wheel Nuts
interval to check the wheel nuts. The correct torque is
105115 ft.lbs. (142156 Nm) [A].
Tire Rotation
Check the tires regularly for wear, damage and pressure.
(See SPECIFICATIONS Section 8 for the correct tire
pressure.)
Rear tires usually wear faster than front tires. To keep tire
wear even, move the front tires to the rear and rear tires P00167
to the front [B].
It is important to keep the same size tires on each side of
the loader to avoid excessive wear. If different sizes are
B
used, each tire will be turning at a different speed and
cause excessive wear. The tread bars of all the tires must
face the same direction.
Recommended tire pressure must be maintained to avoid
excessive tire wear and loss of stability and handling
capability. Check for the correct pressure before
operating the loader.
Tire Mounting
Tires are to be repaired only by an authorized person
using the proper procedures and safety equipment. Tires C01965
and rims must always be checked for correct size before
mounting. Check rim and tire bead for damage.
The rim flange must be cleaned and free of rust. The tire
bead and rim flange must be lubricated with a rubber
lubricant before mounting the tire, avoid excess pressure
which can rupture the tire and cause serious injury or
death. During inflation of the tire, check the tire pressure
frequently to avoid overinflation.
Do not inflate tires above specified pressure.
Failure to use correct tire mounting procedure
can cause an explosion which can result in
injury or death. W20781285
742B, 743B Loader

Service Manual
FINAL DRIVE TRANSMISSION (CHAINCASE)
Checking And Adding Oil
A
The chaincase contains the final drive sprockets and
chains and uses the same type of oil as the
hydraulic/hydrostatic system. (See SPECIFICATIONS 1
Section 8.)
To check the chaincase oil level, use the following
procedure:
Drive the loader onto a level surface. Stop the engine.
Remove the plug (Item 1) [A] at the front of the chaincase
housing.
P00168
If oil can be reached with the tip of the your finger through
the hole the oil level is correct.
If the level is low, add oil through the check plug hole until
the oil flows from the hole. Install and tighten the plug.
742B, 743B Loader

127 Service Manual
LUBRICATING THE BOBCAT LOADER
A
Procedure
Lubricate the Bobcat loader as specified in the SERVICE 1
SCHEDULE Page 11 for the best performance of the
loader.
Always use a good quality lithium based multipurpose
grease when you lubricate the loader. Apply the lubricant
until the extra grease shows.
Lubricate the following locations on the loader:
1. Rod End Lift Cylinder (both sides) [A].
P00175
2. Base End Lift Cylinder (both sides) [B].

B 2
P00190
3. Lift Arm Pivot Pin (both sides) [C].

C
P00189
4. Base End Tilt Cylinder [D].

D
P00172
742B, 743B Loader

128 Service Manual
LUBRICATING THE BOBCAT LOADER (Contd)
A
Procedure (Contd)
5. Rod End Tilt Cylinder [A].
P00168
6. BobTach Pivot Pin (both sides) [B].

B 6
7. BobTach Wedge (both sides) [B].
7
P00173
8. 250 Hours: Steering Lever Shaft (2) [C]. C
P00198
9. 250 Hours: Steering Lever Shaft Bearings (2) [D]. D

9
9
P00191 P00195
742B, 743B Loader

129 Service Manual
UJOINT LUBRICATION
742B(S/N509418001&Above),743B(S/N509318001&Above)ServiceManual#6720772PreventiveMaintenanceSectionPart2of2
A
Procedure
interval when to lubricate the Ujoint grease fittings.
B03371
Raise the operator cab. (See Page 15.)
Use the special Ujoint grease (P/N 6599719) to assure
correct lubrication for the Ujoint.
P00200
REMOTE START SWITCH

Procedure
B
The tool listed will be needed to do the following
procedure:
MEL1138A Remote Start Switch
The remote start switch is required when the operator cab
is int he raised position for service and the service
technician needs to start the engine. The wire harness
must be separated at the operator cab and engine wiring
harness connectors.
Place the loader on jackstands before centering the
steering linkage, checking the main relief valve, or check
pump flow.
B09842

death.
W20170286
The remote start switch is connected to the engine

harness connector.
This remote start switch is required when the service
technician is adjusting the steering linkage or checking
the hydraulic or hydrostatic system
742B, 743B Loader

130 Service Manual
HYDRAULIC SYSTEM
Page
Number
HYDRAULIC CONTROL PEDALS
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218 HYDRAULIC
SYSTEM
HYDRAULIC CONTROL VALVE
Adjusting The Main Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Checking The Main Relief Valve W/Auxiliary Couplers (Opt.) . . . . . . . . 27
Checking The Main Relief Valve W/O Auxiliaries . . . . . . . . . . . . . . . . . . 28
Main Relief Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . 29
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
HYDRAULIC FLUID FILTER HOUSING

HYDRAULIC FLUID RESERVOIR
HYDRAULIC PUMP
Checking The Output Of The Hydraulic Pump . . . . . . . . . . . . . . . . . . . . . 212
HYDRAULIC SYSTEM INFORMATION

Flare Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Oring Face Seal Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Straight Thread Oring Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Tubelines And Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
LIFT CYLINDER
Checking The Lift Cylinder(s) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
PEDAL INTERLOCK LINKAGE

Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219
PORT BLOCK
Case Drain Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
Cold Weather ByPass Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
TILT CYLINDER
Checking The Tilt Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
TROUBLESHOOTING
Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
742B, 743B Loader

Service Manual
TROUBLESHOOTING
The following troubleshooting chart is provided for
assistance in locating and correcting problems which are
most common. Many of the recommended procedures
must be done by authorized Bobcat Service Personnel
only. Check for correct function after adjustments,
repairs or service. Failure to make correct
repairs or adjustments can cause injury or
death.
W20041285
PROBLEM CAUSE
The hydraulic system will not operate. 1, 2, 3

Slow hydraulic system action. 1, 3, 4, 5, 6
Hydraulic action is not smooth. 1, 4, 5, 6, 7
Lift arms go up slowly at full engine RPM. 1, 3, 4, 6, 7, 8, 9

The lift arms or BobTach will move when the pedal is in neutral position. 4
The lift arms come down with the pedal in the neutral position. 4, 9, 10
KEY TO CORRECT THE CAUSE
1. The fluid level is not correct.

2. The pedal linkage is disconnected.
3. The hydraulic pump has damage.
4. The pedal linkage is not adjusted correctly.

5. Relief Valve is not at the correct pressure.
6. Suction leak on the inlet side of the hydraulic pump.
7. Fluid is cold.
8. Internal leak in the lift cylinder(s).
9. External leak from the lift cylinder(s).

10. Leaking seal in port relief valve, lift section.
742, 743B Loader

21 Service Manual
HYDRAULIC SYSTEM INFORMATION
A Mark a Line on Nut
Flats of Both Nuts
When repairing hydrostatic and hydraulic Tighten to Correct

systems, clean the work area before Amount from Chart
disassembly and keep all parts clean. Always
use caps and plugs on hoses, tubelines and
ports to keep dirt out. Dirt can quickly damage
the system.
I20030888
A01897
Flare Connections
Use the following procedure to tighten the flare fitting:
B
Tube Size Rotate No.
Wrench Size Outside Dia. Thread Size of Hex Flats
Tighten the nut until it makes contact with the seat. Make
a mark across the flats of both the male and female parts 5/8 5/16 1/2 20 21/2
of the connection [A]. 11/16 3/8 9/16 18 2
7/8 1/2 3/4 16 2
Use the chart to find the correct tightness needed [B]. If 1 5/8 7/8 14 11/2 2
the fitting leaks after tightening, disconnect it and inspect
the seat area for damage. 11/4 3/4 11/16 12 1
13/8 1 15/16 12 3/4 1
2 11/4 15/8 12 3/4 1
21/4 11/2 17/8 12 1/2 3/4
Oring Face Seal Connection

When the fitting is tightened, you can feel when the fitting
C
is tight to eliminate leakage caused by under or over
torqued fittings. Use vaseline petroleum jelly to hold the
Oring in position until the fittings are assembled [C].
B07575
Straight Thread Oring Fitting

Lubricate the Oring before installing the fitting. Loosen D
the jam nut and install the fitting. Tighten the jam nut until
the washer is tight against the surface [D].
Nut Nut
Tubelines And Hoses
Replace any tubelines that are bent or flattened. They will Washer Washer
restrict flow, which will slow hydraulic action and cause Oring
heat.
Oring
Replace hoses which show signs of wear, damage or
weather cracked rubber.
Always use two wrenches when loosening and tightening
hose or tubeline fittings. A01852
742B, 743B Loader

22 Service Manual
LIFT CYLINDER
Checking The Lift Cylinder(s)
A
Lower the lift arms.
Stop the engine.
Activate the lift pedal to release the hydraulic pressure.
Open the rear door.
B09855
Diesel fuel or hydraulic fluid under pressure

can penetrate skin or eyes, causing serious B
injury or death. Fluid leaks under pressure may
not be visible. Use a piece of cardboard or wood
to find leaks. Do not use your bare hand. Wear
safety goggles. If fluid enters skin or eyes, get
immediate medical attention from a physician
familiar with this injury.
W20720496
Disconnect the hose from the tubeline which comes from

the base end of the lift cylinder; left [A], right [B].
Only check one cylinder at a time.
Put a plug in the tubeline. Put the parking brake in the lock B09856
position and lower the seat bar. Start the engine and push
the top (toe) of the lift pedal.
If there is any leakage from the open port, remove the lift C
cylinder for repair.
Repeat the procedure to check the lift cylinder on the
other side.
Removal And Installation

Stop the engine. Activate the lift pedal to release the
hydraulic pressure.
Raise the operator cab. (See PREVENTIVE
MAINTENANCE Section 1.) Remove the lock bolt and nut
at the rod end of the lift cylinder [C].
B09795
Installation: Tighten the bolt and nut to 1820 ft.lbs. D

(2427 Nm) torque.
Remove the rod end pin [D].
B09794
742, 743B Loader

23 Service Manual
LIFT CYLINDER (Contd)
A
Removal And Installation (Contd)
Remove the lock bolt at the base end pivot pin [A].
B09896
Remove the base end pivot pin [B].

B
B09857
Disconnect the hydraulic hoses at the tubelines; left [C],

right [D]. C
Slide the cylinder forward and remove it from the loader.
SEE THE COMPONENT REPAIR MANUAL FOR
HYDRAULIC CYLINDERS FOR DISASSEMBLY AND
ASSEMBLY PROCEDURE.
B09855
B09856
742B, 743B Loader

24 Service Manual
TILT CYLINDER
A
Checking The Tilt Cylinder
Remove the bucket or attachment. Roll the BobTach
frame fully backward. Stop the engine. Activate the tilt
pedal to release the hydraulic pressure.

can penetrate skin or eyes, causing serious B09787
B
W20720496
Disconnect the hose which goes to the base end of the tilt
cylinder [A].
Put a plug in the hose.
Put the parking brake in the locked position and lower the
seat bar.
Start the engine and push the bottom (heel) of the tilt
CD08709
pedal.
If there is leakage from the open port, remove the tilt
cylinder for repair. C
Remove the bucket or attachment. Roll the BobTach
frame fully forward.
Stop the engine. Push the tilt pedal to release the
hydraulic pressure.
Disconnect the hydraulic hoses [A].
Remove the nut at the rod end pivot pin [B].

Installation: Tighten the nut to 1820 ft.lbs. (2427 Nm) CD08710
torque.
Remove the rod end pivot pin [C].

D
NOTE: See MAIN FRAME Section 5 to install the rod
end seals.
Remove the lock bolt at the base end pivot pin [D].
Installation: Tighten the bolt and nut to 1820 ft.lbs.
(2427 Nm) torque.
B04402
742, 743B Loader

25 Service Manual
TILT CYLINDER (Contd)
A
Remove the base end pivot pin [A].
Remove the tilt cylinder from the loader lift arms.
HYDRAULIC CYLINDERS FOR DISASSEMBLY AND
ASSEMBLY.
B04401
742B, 743B Loader

26 Service Manual
HYDRAULIC CONTROL VALVE
A
Checking The Main Relief Valve W/Auxiliary
Couplers (Opt.)
The tools listed will be needed to do the following
procedure:
MEL1238 Hydraulic Tester
MEL10006 Hydraulic Test Kit
Stop the engine. Activate the right steering lever to
release the hydraulic pressure.
Lift and block the loader. (See PREVENTIVE
MAINTENANCE Section 1.)
B04371
Connect the hydraulic tester to the auxiliary quick
couplers [A].

The hydraulic tester must be in the fully open corners of the frame before running the engine
position before you start the engine. for service. Failure to use jackstands can allow
I20240284 the machine to fall or move and cause injury or
death.
W20170286
Start the engine and run at idle RPM. Engage the right
steering lever into the detent position.
Watch the flow meter at the hydraulic tester to make sure
the flow is correct.
Increase the engine RPM to maximum.
There should be 12.1 GPM (45,8 L/min.) free flow. When the engine is running during service, the
steering levers must be in neutral and the
Turn the restrictor control. at the tester, until the main parking brake engaged. Failure to do so can
relief valve opens. cause injury or death.
W20060284
The correct pressure for the main relief valve is
11501400 PSI (1551416548 kPa) free flow at the quick
couplers.
If not, stop the engine. Replace or adjust the main relief
valve. (See Page 29.)
742, 743B Loader

27 Service Manual
HYDRAULIC CONTROL VALVE (Contd)
A
Checking The Main Relief Valve W/O Auxiliaries
procedure:
Stop the engine. Activate the tilt pedal to release the
hydraulic pressure.
B09787
Disconnect the hydraulic hoses at the tilt cylinder [A].
Connect the hydraulic tester to the tilt cylinder hoses [B]. B

Have a second person in the operator seat, with the seat
bar in the down position and the parking brake in the
locked position.
Start the engine and run at idle RPM.
Push the tilt pedal at the top (toe) or bottom (heel) until the
hydraulic tester shows the correct fluid flow through the
flow meter.
Increase the engine RPM to maximum.
There should be 12.1 GPM (45,8 L/min.) free flow.
B09849
Turn the restrictor control, at the tester, to increase the
pressure until the main relief valve opens.
The correct pressure is 22502400 PSI (1551416548
kPa) free flow.
If not, stop the engine. Replace or adjust the main relief
valve. (See Page 29.)
When an engine is running in an enclosed

area, fresh air must be added to avoid
concentration of exhaust fumes. If the engine
is stationary, vent the exhaust outside.
Exhaust fumes contain odorless, invisible
gases which can kill without warning.
W20501285
742B, 743B Loader

28 Service Manual
A
Main Relief Valve Removal And Installation
Stop the engine. Activate the hydraulic controls to release
the hydraulic pressure.
Open the rear door. Raise the operator cab. (See
PREVENTIVE MAINTENANCE Section 1.)
Clean the area around the control valve. 1
The main relief valve (Item 1) [A] is located at the rear of
the control valve.
NOTE: It may be necessary to disconnect some

B09891
tubelines for better clearance to the main
relief valve.
B
Use a deep socket and extension, remove the main relief
valve [B].
Installation: Always us NEW Orings, when installing
the main relief valve. Clean and inspect the relief valve
and replace as needed.
B09894
Adjusting The Main Relief Valve

Clean the area around the main relief valve.
C
Remove the cap from the main relief valve [C].
B09892
Loosen the lock nut. Use an allen wrench and adjust the
main relief valve [D]. D
Check the main relief valve with the hydraulic tester
again, until the pressure setting is correct. (See Page 27
or 28.)
B09893
742, 743B Loader

29 Service Manual
A
When repairing hydrostatic and hydraulic

systems, clean the work area before
the system. B09819
I20030888
B
MAINTENANE Section 1.)

corners of the frame before running the engine B09859
death.
W20170286
C

Clean the area around the control valve.
Remove the port block from the loader. (See Page 214.)
Disconnect the hose from the control valve [A].
Disconnect the linkage at the control valve [B] & [C]. B09821
Disconnect all the tubelines from the control valve [D]. D
B09858
742B, 743B Loader

210 Service Manual
A
Remove the mounting bolts and nuts from the control
valve [A] & [B].
Installation: Tighten the mounting bolts and nuts to
180200 in.lbs. (2123 Nm) torque.

HYDRAULIC CONTROL VALVE DISASSEMBLY AND
ASSEMBLY PROCEDURE.
B09818
B09809
742, 743B Loader

211 Service Manual
HYDRAULIC PUMP
Checking The Output Of The Hydraulic Pump
A
procedure:
NOTE: Make sure that all the air is removed from the
system before beginning the test. Air in the
system can give an inaccurate test.

for service. Failure to use jackstands can allow B09860
death.
W20170286

Disconnect the OUTLET hose at the pump. Connect the systems, clean the work area before
INLET hose of the tester to the OUTLET of the hydraulic disassembly and keep all parts clean. Always
pump [A]. use caps and plugs on hoses, tubelines and
Connect the OUTLET hose from the tester to the hose the system.
which was removed from the pump [A]. I20030888
NOTE: Make sure the restrictor control on the tester

is fully open.
Disconnect both hoses at the tilt cylinder and install plugs.
Start the engine and run at idle RPM. Make sure the tester
is connected correctly. If no flow is indicated on the tester,
the hoses are connected wrong. With the hoses
connected correctly, increase the engine speed to full
RPM.
Warm the hydraulic fluid to 140F. (60C.) by turning the
restrictor control on the tester to about 1000 PSI (6895
kPa). DO NOT exceed system relief pressure.
Open the restrictor control and record the free flow GPM
(L/min.) at full RPM.
Activate the tilt pedal. Record the highest pressure PSI
(kPa) and flow GPM (L/min.) at full RPM.
The high pressure flow must be at least 80% of free flow.
HIGH PRESSURE FLOW (GPM)
%= X 100
FREE FLOW (GPM)
A low percentage may indicate a failed hydraulic pump or
it may be caused by air in the system. Make sure all the
air is removed from the system.
Refer to the SPECIFICATIONS Section 8 for system
relief pressure and full RPM. The system relief pressure
must be per specifications before the test is run.
742B, 743B Loader
HYDRAULIC PUMP (Contd)
A

ports to keep dirt out. Dirt can quickly damage CD09061
the system.
I20030888
B
Remove the fluid from the hydraulic fluid reservoir.
Disconnect the hose at the hydraulic pump [A].
Disconnect the hose at the outlet of the pump [B].
CD09062
Remove the pump mounting bolts. C

Installation: Tighten the bolts to 2528 ft.lbs. (3438
Nm) torque.
Remove the hydraulic pump [C].
CD09060
Installation: Install a new large Oring (Item 1) [D]. D

HYDRAULIC PUMPS FOR DISASSEMBLY AND
ASSEMBLY PROCEDURE.
1
CD09059
742, 743B Loader

PORT BLOCK
A
procedure:
MEL1272 Plug and Cap Set
When repairing hydrostatic and hydraulic B09790

ports to keep dirt out. Dirt can quickly damage B
the system.
I20030888

Clean the area around the port block.
Disconnect the hydraulic pump hose from the port block
[A].
B09811
Disconnect the inlet hose [B].

C
Disconnect the wire at the sender switch [C].
B09812
Disconnect the case drain hoses at the port block [D]. D
B09803
742B, 743B Loader

214 Service Manual
PORT BLOCK (Contd)
A
Disconnect the tee fitting at the port block [A].
B09791
Remove the nut which fastens the port block to the

mounting bracket [B]. B
B09814
Remove the port block from the mounting bracket [C].

C
B09789
Cold Weather ByPass Valve

Disconnect the tee fitting. D
Remove the fitting from the port block [D].
NOTE: When installing the fitting make sure to

tighten the fitting to get the correct spring
tension on the poppet.
B09815
742, 743B Loader

215 Service Manual
PORT BLOCK (Contd)
A
Cold Weather ByPass Valve (Contd)
Remove the poppet and spring [A].
Clean and inspect the parts. Check the seat in the fitting
for damage.
Always use new Oring when installing the fitting.
B09802
Case Drain Relief Valve

Remove the plug at the port block [B].
B
B09788
Remove the spring and poppet [C].

Clean and inspect the parts. Always use new Oring
C
when installing the plug.
B09801
742B, 743B Loader

216 Service Manual
HYDRAULIC FLUID RESERVOIR
A
Use a transfer pump or hand pump and remove the fluid
from the hydraulic reservoir.
Disconnect the oulet hose at the reservoir [A].
B04920
Remove the bolt at the holding strap [B]. B

Remove the hydraulic reservoir from the loader.
B09864
742, 743B Loader

217 Service Manual
HYDRAULIC CONTROL PEDALS
A
Remove the bolt and nut at the linkage [A].
Check the rubber bushing in the pedal for wear and
replace as needed.
B08831
Remove the two mounting bolts [B].

B
B09793
Remove the pedal from the loader [C].

C
Adjustment
After installing the pedal, adjust the pedal so that there is
clearance under the rear of the pedal and the valve spool
will travel full stroke without the pedal hitting.
AVOID INJURY OR DEATH B08833

Adjust locking tabs on pedal control linkage so
that lift and tilt control pedals are locked in
neutral when the seat bar is up.
W21041285
742B, 743B Loader

218 Service Manual
PEDAL INTERLOCK LINKAGE
A
Installation
If the pedal interlock linkage was removed, use the 4
following procedure to install the linkage [A]. 5 1
2
Install the bolts (Item 1) [A] from the outside the fender.
Install the plastic washer (Item 2) [A].
Install the interlock (Item 3) [A].
Install the plastic washer (Item 4) [A].
3
Put LOCTITE #242 on the threads of the bolts.
D01548
Install the special nuts (Item 5) [A]. make sure the special
nut goes tight against the fender and that the plastic
washer (Item 2 & 4) [A] go over the shoulder of the the
special nut.
B
Tighten the special nut to 25 ft.lbs. (34 Nm) torque.
AVOID INJURY OR DEATH 1

Adjust locking tabs on pedal control linkage so
that lift and tilt control pedals are locked in
neutral when the seat bar is up. B04043
W21041285
Adjustment
Check that the pedal interlock linkage is free and locks the
pedals when returned to neutral position.
Check that the tab goes into the slot at the interlock [B].
If not, loosen the bolts (Item 1) [B] and adjust the tab for
engagement.
Installation: Tighten the bolts to 25 ft.lbs. (34Nm)
torque.
742, 743B Loader

219 Service Manual
HYDRAULIC FLUID FILTER HOUSING
742B(S/N509418001&Above),743B(S/N509318001&Above)ServiceManual#6720772HydraulicSystemSection
A
Remove the hydraulic filter.
Remove the hoses and tubelines from the filter head.
Remove the filter head [A].
B04904
Put the filter head in a vise. Remove the cap, spring and
poppet [B]. B
Check the poppet and the seating area for damage.
Replace the parts as needed.
NOTE: Always use new Orings when installing the

bypass valve.
B04906
742B, 743B Loader

220 Service Manual
HYDROSTATIC SYSTEM
Page
Number
FRONT PANEL
HYDROSTATIC MOTOR
HYDROSTATIC PUMP
Charge Pressure Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 312 HYDROSTATIC
Checking Charge Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 312 SYSTEM
Checking High Pressure Relief Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . 313
High Pressure Hose Routing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 318
Hydrostatic Pump Rear Mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 317
Tow Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 318
HYDROSTATIC SYSTEM INFORMATION

High Pressure Relief/Replenishing Valve Function . . . . . . . . . . . . . . . . . 32
STEERING LEVERS
Repairing The Steering Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
STEERING LINKAGE
Repairing The Pintle Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Steering Linkage Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
TROUBLESHOOTING
Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
TIGHTEN ALL HARDWARE PER SIZE TO GRADE 5 TORQUE (SEE

STANDARD TORQUE SPECIFICATIONS FOR BOLTS, SECTION 9)
UNLESS OTHERWISE SPECIFIED.
742B, 743B Loader

Revised July 96 Service Manual
TROUBLESHOOTING
Chart
The following troubleshooting chart is provided for
assistance in locating and correcting problems which are
most common. Many of the recommended procedures
must be done by authorized Bobcat Service Personnel Check for correct function after adjustments,
only. repairs or service. Failure to make correct
repairs or adjustments can cause injury or
death.
W20041285
PROBLEM CAUSE
No drive on one side, in one direction. 1, 2, 3, 4, 5

No drive on one side in both directions. 2, 3, 5, 6, 7, 8
The loader does not move in a straight line. 2, 3, 4, 6, 8, 9, 10
The hydrostatic system is overheating. 4, 11, 12, 13, 14, 15

The warning light comes ON (Low charge pressure). 11, 15, 16, 17, 18
1. The hydrostatic system has a fluid leak.

2. The steering linkage needs adjustment.
3. The high pressure replenishing valve(s) are damaged.
4. the shuttle valve in the hydrostatic motor is not working correctly.
5. The valve plate seals in the hydrostatic motor are damaged.
6. The hydrostatic pumps have damage.
7. The final drive chain is broken.
8. The hydrostatic motor has damage.
9. the tires do not have the correct tire pressure.
10. The tires are not the same size.
11. The hydraulic fluid is not at the correct level.
12. The oil cooler has a restriction.
13. The temperature sending switch is not operating correctly.
14. The control valve is not operating correctly.
15. The loader is not being operated at the correct RPM.
16. The sender is defective.
17. Pump is defective or worn hydrostatics.
18. Hydraulic filter is plugged.
742B, 743B Loader

31 Service Manual
HYDROSTATIC SYSTEM INFORMATION
A CHARGE OIL
When repairing hydrostatic and hydraulic FUNCTION 1

systems, clean the work area before Valve Moves for Charge
disassembly and keep all parts clean. Always Oil Replacement
the system.
I20030888
High Pressure Relief/Replenishing Valve Function

The valves for forward movement are different from the FUNCTION 2 Valve Stays on Seat to
valves for reverse travel. Hold High Pressure for Drive
The high pressure relief/replenishing valves for forward

travel, also release very high pressure.
The functions of the replenishing valves are:
1. To give replacement fluid to the low pressure side of

the hydrostatic circuit. Replacement fluid is needed FUNCTION 3
because of normal internal leakage and the Valve Release Very High
controlled flow to the oil cooler for cooling; Function Pressure to Protect System
1 [A] and Function 1 [B].
B02805
2. To keep high pressure fluid out of the low pressure
side of the hydrostatic circuitry; Function 2 [A] and
Function 2 [B].
B
3. To release high pressure caused by moving forward CHARGE OIL
with a heavy load on the loader, Function 3 [A].
Valve Moves for Charge

Oil Replacement
FUNCTION 1
Valve Stays on Seat to

Hold High Pressure for Drive
FUNCTION 2
B02804
742B, 743B Loader

32 Service Manual
FRONT PANEL
A

death.
W20170286
CD12707
Raise the lift arms and install the lift arm support devise.
(See PREVENTIVE MAINTENANCE Section 1.) Stop
B
the engine.
Remove the nut at the parking brake pedal [A].
Using a drill, remove the pop rivet heads from the parking
brake linkage rubber boot [B].
CD12832
Slide the rubber boot away from the front panel [C].
C
CD12709
Remove the bolts at the foot rests (both sides) [D].

D
CD12710
742B, 743B Loader

33 Service Manual
FRONT PANEL (Contd)
A
Remove all the bolts at the left side of the front panel [A].
B09833
Remove all the bolts at the right side of the front panel [B].
B
B09837
Remove the hand grip by plugging the hole at the bottom

of the steering lever and using air pressure to remove the
hand grip (both sides) [C]. C
B07876
Lift and remove the front panel from the loader frame [D].
D
B09922
742B, 743B Loader

34 Service Manual
STEERING LEVERS
A
Remove the front panel. (See Page 33.)
Disconnect the steering linkage at the steering levers [A].
Installation: Tighten the bolts and nuts to 23 ft.lbs. (31
Nm) torque.
Disconnect the auxiliary linkage from the steering levers
if so equipped.
B09908
Hold the nuts inside the loader frame [B] and remove the
bolts at the pivot bearing [C]. B
B09832
B09989
Remove the bolts and nuts at the pivot bearing [D]. D
B09988
742B, 743B Loader

35 Service Manual
STEERING LEVERS (Contd)
A
Lift and remove the steering lever assembly from the
loader [A].
B09854
Repairing The Steering Levers

Remove the rubber bushings and teflon bushings from
B
the steering levers.
Washer
Install new rubber bushings into the steering levers, using
two sockets and a vise [B]. Neoprene
Bushing
B10030 B10032
Install new teflon bushings when installing the two

steering assemblies together [C].
C
B10031
742B, 743B Loader

36 Service Manual
STEERING LINKAGE
A
Steering Linkage Adjustment

death.
W20170286
B
Connect a remote start switch. (See PREVENTIVE
Loosen the nuts and bolts at both steering levers [A].
Loosen the nuts and bolts at the front and rear pintle
levers [B].
Start the engine and run at idle RPM.
B09970
Loosen the bolts that connect the front and rear pintle C
levers to the pintle lever bars [C].
Move the steering lever for the rear pintle arm, until the
tires do not mover (neutral).
Push the top (slotted hole) of the pintle bar (Item 1) [D]
against the lobe on the pintle lever with the transmission
still in neutral.
B09888
Tighten the rear pintle bar bolts to 28 ft.lbs. (38 Nm)
torque.
Move the steering lever, fro the front pintle lever, until the D
tires do not run (neutral).
Push the pintle bar (Item 2) [D] against both lobes of the
pintle lever with the transmission still in neutral.
Tighten the front pintle bar bolts to 28 ft.lbs. (38 Nm)
toque.
Move both steering levers backward and forward and let
the transmission return to neutral. If the transmission
1
does not return to neutral, repeat the adjustment again.
2
Install new lock nuts at the steering linkage and tighten to
23 ft.lbs. (31 Nm) torque.
C02556
742B, 743B Loader

STEERING LINKAGE (Contd)
A
Disconnect the steering linkage at both pintle levers [A].
Installation: Install new lock nuts and tighten to 23
ft.lbs. (31 Nm) torque.
B09970
At the centering spring bolt loosen the lock nut and turn
the bolt out of the bracket [B].
B
B09897
Loosen the bolt at the rear pintle lever [C]. C
B09841
Loosen the bolt at the front pintle lever [D].

D
Installation: Install the key in the pintle shaft. Tighten the
pintle lever bolt to 1820 ft.lbs. (2427 Nm) torque.
B09902
742B, 743B Loader

STEERING LINKAGE (Contd)
A
Remove the guide bar, bushings and pintle levers as an
assembly [A].
Installation: Adjust the steering linkage for neutral. (See
Page 37.)
B09910
Repairing The Pintle Lever

Remove the bolt at the lobes on the pintle lever [B].
B
Nm) torque.
Remove the rubber bushing from the pintle lever.
B04476
Install a new rubber bushing into the pintle lever [C].

C
Neoprene Washer
Bushing
B04388
Press the rubber bushing into the pintle lever, using two
sockets and a vise [D].
D
B04471
742B, 743B Loader

39 Service Manual
HYDROSTATIC MOTOR
A

the system. CD12835
I20030888
B
Remove the bolts from the motor cover [A].
Remove the motor cover [B].
CD12836
Mark both high pressure hoses for correct installation.

C
Disconnect both high pressure hoses from the motor [C]
& [D].
CD12837
CD12838
742B, 743B Loader

310 Service Manual
HYDROSTATIC MOTOR (Contd)
A
Disconnect the case drain hose (Item 1) [A].
CD12839
Remove the bolts from the motor mounting flange [B].

Installation: Tighten the bolts to 90100 ft.lbs.
B
(122136 Nm) torque.
B12840
Remove the hydrostatic motor from the motor carrier [C].
NOTE: When connecting the high pressure hoses,

C
See Page 317 for the correct hose routing.

HYDROSTATIC MOTOR DISASSEMBLY AND
ASSEMBLY PROCEDURE.
B12841
742B, 743B Loader

311 Service Manual
HYDROSTATIC PUMP
Checking Charge Pressure
A
procedure:
MEL1173 Test Kit
List and block the loader. (See PREVENTIVE
MAINTENANCE Section 1.) 1
CD12842

corners of the frame before running the engine B
death.
W20170286

Connect the remote start switch. (See PREVENTIVE
Disconnect the wires from the charge pressure switch
[A].
B09839
Remove the charge pressure switch (Item 1) [A].
Connect a pressure gauge to the port. C
Start the engine and check the charge pressure. The
correct pressure is 95115 PSI (655793 kPa).
Charge Pressure Relief Valve

Remove the plug at the charge pressure relief valve [B].
Remove the poppet and spring [C].

Check the parts for wear or damage.
B09905
742B, 743B Loader

312 Service Manual
HYDROSTATIC PUMP (Contd)
A
Checking High Pressure Relief Valves

death.
W20170286
B
NOTE: To remove the high pressure relief valve from
the left side of the hydrostatic pump, you
must remove the steering linkage. (See Page
38.)
If there is a loss of drive in one direction, to one side of the

loader, use this procedure to check the high pressure
replenishing valves:
Remove the plugs at the right and left side of the
hydrostatic pump [A] & [C]. B09907
Remove the high pressure relief valve and the

replenishing valves [B] & [D]. C
Exchange the valves (put in opposite ports) and check for
loss of drive on the opposite side of the loader.
If there is a loss of drive to the opposite side of the loader,
the valve which controls that side of the loader must be
replaced.
B09840
B09904
742B, 743B Loader

313 Service Manual
A

the machine to fall or move and cause injury or CD12843
death.
W20170286
B
Disconnect the steering linkage at the steering levers and
pintle lever [A].
Installation: Tighten the bolts and nuts to 23 ft.lbs. (31
Nm) torque. See Page 37 for neutral adjustment.
Disconnect the wire at the port block [B].

CD12844
Disconnect the wires at the charge pressure sending

switch [C]. C
CD12842
Disconnect the outlet hose from the hydraulic pump [D].

D
CD12845
742B, 743B Loader

314 Service Manual
A
Disconnect the inlet hose for the hydraulic pump [A].
CD12846
Disconnect the hose from the tee fitting on the top of the
pump [B]. B
B12847
Disconnect the hose from the port block [C].

C
CD12848
Disconnect the high pressure hoses from the hydrostatic

motor (both sides) [D].
D
CD12837
742B, 743B Loader

315 Service Manual
A
Loosen the mounting bolts for the fuel tank/hydraulic
reservoir mounting strap.
Lift the fuel tank for clearance.
Remove the left mounting bolt, washers, rubber bushing
and nut [A].
CD12849
Remove the right mounting bolt, washers, rubber bushing

and nut [B]. B
Installation: See Page 317 for the correct hydrostatic
pump mounting height.
Connect chain hoist to the hydrostatic pumps.
CD12850
Remove the nuts and bolts at the front mounting bracket

[C].
C
Slide the hydrostatic pumps forward and out of the ujoint
at the engine.
Lift the pump from the loader.
Installation: Make alignment of the splines at the
hydrostatic pump shaft and ujoint when installing the
pumps.
Use special lubricant (P/N 6599719) on the Ujoint
splines.
HYDROSTATIC PUMP FOR DISASSEMBLY AND CD12851
ASSEMBLY PROCEDURE.
742B, 743B Loader

316 Service Manual
Hydrostatic Pump Rear Mount
A
If the rear pump mount is removed, make sure to not the
location of the washer(s) between the mount and the
frame.
These washers (Item 1) [A] must be installed at the
correct location to give the pump and engine the correct
alignment.
10.00 .06
(254 mm) 1.52 Engine Mounting
Plate
B06938
High Pressure Hose Routing

Make sure to connect the high pressure hoses to the
B
correct ports of the hydrostatic pumps and motors [B].
Tow Valves
Front
of
Loader
When repairing hydrostatic and hydraulic C02767

ports to keep dirt out. Dirt can quickly damage C
the system.
I20030888

procedure:
MEL11792 Towing Tool
Clean the area around the two high pressure relief valves
on the pumps.
Remove the plug, spring and high pressure relief from the
front and rear pump [C]. B09846
Install the towing tools (Item 1 & 2) and then only install
the plugs [D].
D
Now the loader can be moved (towed) at a slow speed (2
MPH) for a short distance such as 75 to 100 feet (23 to
30 m).
NOTE: Make sure to remove the tow tools before

trying to operate the loader.
B09847
742B, 743B Loader

DRIVE SYSTEM
Page
Number
AXLE SEAL
AXLE, SPROCKET AND BEARINGS
CHAINCASE FLUID
Replacing the Chaincase Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 419
DRIVE CHAIN
MOTOR CARRIER
Disassembly And Assembly (Early Models) . . . . . . . . . . . . . . . . . . . . . . . 410 DRIVE
Disassembly And Assembly (Later Models) . . . . . . . . . . . . . . . . . . . . . . . 410 SYSTEM
Removal And Installation (Early Models) . . . . . . . . . . . . . . . . . . . . . . . . . 410
Removal And Installation (Later Models) . . . . . . . . . . . . . . . . . . . . . . . . . 49
Shaft Seal Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
PARKING BRAKE
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Brake Block And Pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Brake Disc Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Rear Transmission Cover Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

742B, 743B Loader

Revised Sept. 93 Service Manual
PARKING BRAKE
Adjustment
A
When the parking brake is in good condition and adjusted
correctly, it will keep the loader from moving when the
steering levers are moved.
Turn the nut (Item 1) [A] to adjust eh parking brake.
There must be 3/4 inch (19 mm) movement from the top
of the cover (not the bolt head) to the bottom edge (heel)
of the brake pedal.
P02450
NOTE: If the correct adjustment can not be obtained
by turning the nut, the brake lever must be
adjusted using the following procedure.
B
Loosen the nut (Item 1) [A].
Disconnect the spring from the brake lever [B].
P02294
Remove the adjustment nuts on the brake lever.

Loosen the bolt on the brake lever [C].
C
Do not remove the bolt.
P02291
Use a pry bar and hammer, pry up on the lever and hit the
bolt with the hammer until the brake lever is loose [D]. D
Remove the bolt and brake lever.
Turn the brake block shaft counterclockwise until the
brake pads make contact with the brake discs.
Install the brake lever. Install the bolt and tighten to 6570
Adjust the parking brake again.
P02296
742B, 743B Loader

PARKING BRAKE (Contd)
A
Raise the lift arms. (See PREVENTIVE MAINTENANCE
Section 1.)
Remove the nut from the lift pedal linkage [A].
Remove the front panel. (See HYDROSTATIC SYSTEM
Section 3.)
Remove the steering lever assembly. (See
HYDROSTATIC SYSTEM Section 3.) P02430
Disconnect the lift linkage from the control valve spool

[B].
B
P02285
Remove the nut from the linkage crossmember bolt [C]. C
P02299
Remove the linkage crossmember [D]. D

Remove the plastic washer (Item 1) [D] and check for
wear and replace as needed.
P02297
742B, 743B Loader

A
NOTE: If the brake block and pads are going to be

disassembled, loosen the brake lever bolt
[A]. Use a pry bar and hammer, pry up on the
lever and hit the bolt until the brake lever is
loose [B].
Installation: Tighten the bolt to 6570 ft.lbs. (8895

Nm).
P02291
P02295
Remove all the cover bolts. [C].

C
P02298
Remove the cover/brake block assembly [D].

D
Installation: Clean and dry the cover. Clean the surface
on the chaincase where the cover sets. Use a new gasket
under the cover. Align the brake discs so they are
centered and inbetween the brake pads [A].
NOTE: Some early loaders used a sealant to seal
covers. A gasket now available is
recommended.
P01732
742B, 743B Loader

Brake Block And Pads
A
Remove the brake lever bolt [A].
Assembly: Tighten the bolt to 6570 ft.lbs. (8895 Nm)
torque.
CD08829
Remove the brake lever [B].

B
CD08830
Remove the bolt from the brake block [C].

Assembly: Tighten the bolts to 6570 ft.lbs. (8895 C
Nm) torque.
P01725
Remove the guide and pads [D].

D
Assembly: Note location of pads and spacers.
Check the pads for wear and replace them as needed [D].
P01737
742B, 743B Loader

A
Brake Block And Pads (Contd)
Remove the bolts which fasten the brake block to the
cover [A].
Assembly: Tighten the bolts to 6570 ft.lbs. (8895
Nm) torque.
CD08834
Remove the brake block [B].

Assembly: Clean and dry the brake block. Put a bead of
B
R.T.V. sealant on the brake block.
NOTE: Do Not use excessive R.T.V. sealant on the
block. Make sure the brake shaft does not
rub.
CD08835
Remove the shaft from the brake block [C].

C
Assembly: Always install a new Oring when the shaft
is installed. Make sure the shaft rotates freely in the cover.
CD08836
742B, 743B Loader

A
Brake Disc Removal And Installation
To remove the brake discs, the following items must be
removed:
Remove the center cover. (See Page 42.)
Remove the front cover. (See HYDROSTATIC SYSTEM
Section 3.)
D02188
Remove the brake disc snap ring (Item 1) [B]. B
P01733
Remove the brake discs through the front cover hole [C]. C
Check the brake discs for damage. Replace the brake
discs as needed. DO NOT grind the brake discs.
Rear Transmission Cover Installation

When installing the rear cover on the transmission always
use three shoulder bolts where shown [D].
P01731
See your Bobcat loader dealer for the correct shoulder
bolts.
LOCATION
Tighten the bolts to 2025 ft.lbs. (2734 Nm) torque. D
NOTE: Be sure the warning decal is installed on the
inside of the left fender.
MC01707
742B, 743B Loader

MOTOR CARRIER
Shaft Seal Replacement
A
procedure:
MEL1399 Axle Seal Tool
MEL1402 Carrier Seal Tool
Remove the hydrostatic motor. (See HYDROSTATIC
SYSTEM Section 3.)
Use a plier and pull the seal carrier from the motor carrier
[A].
P02097
Remove the old Oring and replace with a new Oring

[B].
B
P01741
Remove the old seals from the seal carrier.

C
Install the seal carrier on the axle seal tool (MEL1399) [C].
CD08845
Install the two seals on the shaft of the motor carrier seal
tool (face the seal lips with one inward and one outward) D
[D].
CD09948
742B, 743B Loader

MOTOR CARRIER (Contd)
A
Shaft Seal Replacement (Contd)
Install the two seals and shaft into the top half of the seal
carrier tool [A].
CD09949
Install the seals/tool assembly into the motor carrier seal

housing [B]. B
Hit the tool with a hammer to seat the seals into the
housing.
CD09950
Install the seal/seal carrier housing into the motor carrier

[C]. C
CD08853
Install the seal carrier installation tool into the seal carrier
housing. Hit the tool with a hammer until the seal housing
is fully seated [D]. D
CD08852
742B, 743B Loader

A
Removal And Installation (Later Models)
Section 1.)
Remove the front panel/steering levers assembly. (See
HYDROSTATIC SYSTEM Section 3.)
Remove the parking brake/cover assembly. (See Page P01735
42.)
Remove the fluid from the chaincase. (See Page 419.) B
Remove the front axle and sprocket. (See Page 414.)
Remove the hydrostatic motor. (See HYDROSTATIC
SYSTEM Section 3.)
Remove from the motor carrier mounting bolts from inside
the chaincase [A].
Installation: Tighten the bolts to 125140 ft.lbs.
(170190 Nm) torque.
Move the motor carrier housing toward the rear of the

chaincase. Remove the rear drive chain from the motor P01734
carrier sprockets [B].
Remove the front drive chain from the motor carrier
sprockets.
C
Remove the motor carrier assembly from the chaincase

[C].
P01736
Installation: When installing the motor carrier with

through holes in the flange, either a gasket or sealant can D
be used.
Put sealant between the bolt heads and the chaincase to
prevent leakage [D].
NOTE: With mounting bolts in place and loose,

center the motor carrier for equal slack of
front and rear chains.
P01730
742B, 743B Loader

A LATER MODELS
Disassembly And Assembly (Later Models)
Use [A] as a guide to disassemble and assemble the
motor carrier. 1
2 3
The correct shaft end play is 0.008 inch (0,2 mm) and is
controlled by the snap ring (item 5) [A].
The snap ring (Item 5) [A] comes in two different widths.
(See Parts Microfiche for the correct part numbers.)
See Page 47 for seal installation.
Lip Faces
IN
8
3 2 5
4 6 7
Lip Faces
OUT
1. Shaft 5. Snap Ring

2. Bearing 6. Oring
3. Race 7. Seal Adapter
4. Snap Ring 8. Seal
TS01131
Disassembly And Assembly (Early Models)

Use [B] to disassemble and assemble the motor carrier.
B EARLY MODELS
1
The correct shaft end play is 0.008 inch (0,2 mm) and is
controlled by the snap ring (Item 7) [B]. 4 5
The snap ring (Item 7) [B] comes in two different widths.
(See Parts Microfiche for the correct part numbers.)
See Page 47 for seal installation. 2
3
6
3 Lip
2 Faces
7 8 9 IN
10
1. Shaft 6. Housing Lip

2. Bearing 7. Snap Ring Faces
3. Race 8. Oring OUT
4. Snap Ring 9. Seal Adapter
5. Spacer 10. Seal
C03083
742B, 743B Loader

AXLE SEAL
A
procedure:
MEL1242 PortaPower
MEL1399 Axle Seal Tool
To loosen the axle hub bolt do the following:
With the loader on the ground, use the correct size socket
and large breaker bar to loosen the hub bolt.
MAINTENANCE Section 1.) CD08855
Remove the tire/wheel assembly.

Installation: Tighten the wheel nuts to 105115 ft.lbs.
B
(142156 Nm) torque.
Remove the bolt and washer [A].
Installation: tighten the bolt to 575625 ft.lbs.

(780848 Nm) torque.
Install wheel nuts on two studs straight across from each
other. Use a hammer to remove the wheel studs [B].
CD08856
Remove the wheel nut and studs from the hub [C]. C
Installation: After the hub has been removed, use a
hammer to install the wheel studs in the hub.
CD08857
742B, 743B Loader

AXLE SEAL (Contd)
A
Install a puller on the wheel hub [A].
CD08858
A slidehammer or PortaPower can be used to remove

the hub. A PortaPower is used in the following
sequence.
B
Install a spacer on the end of the axle and against the
PortaPower ram [B].
NEVER STAND INLINE OF THE HUB WHEN

REMOVING A HUB FROM AN AXLE. The hub
has a tapered fit on the axle end and can come CD08859
off the axle with great force and cause serious
injury.
W21860395
C
Remove the hub from the axle [B].
Remove the key from the axle [C].
CD08860
Drill a small hole into the axle seal [D].

D
CD08861
742B, 743B Loader

AXLE SEAL (Contd)
A
Install a puller and remove the axle seal [A].
NOTE: Check the seal area on the shaft for wear.
If necessary order an axle repair sleeve from Melroe

Parts Sales. (See your dealer when ordering parts.)
CD08862
Installation: Install the new seal on the axle and into the
axle tube [B]. B
Installation: Install the seal driver tool over the axle [B].
CD08863
Installation: Use a hammer, install the new axle seal until

the tool is flush with the edge of the axle tube [C]. C
CD08864
742B, 743B Loader

AXLE, SPROCKET AND BEARINGS
A
the tools listed will be needed to do the following
procedure:
MEL1242 PortaPower
MEL1202B Axle Bearing Service Set
NOTE: The procedure shown for removal and

installation of the axle, sprocket and
bearings is for a front axle, this procedure is
the same for the rear axle.
P02091
Section 1.)
Lift and block the loader. (See PREVENTIVE B
Remove the front panel/steering lever assembly. (See
Remove the front and/or rear cover depending which axle
is being removed.
Remove the fluid from the chaincase. (See Page 419.)
Loosen the axle sprocket bolt when the hub bolt is being P02092
removed [A].
Installation: Tighten the axle sprocket bolt to 220245
ft.lbs. (298332 Nm) torque. C
Remove the axle hub. (See Page 411.)
Install the PortaPower ram between the two sprockets

[B].
Push the axle out until the ram is at the end of the stroke.
Add a spacer and push the axle out again. Repeat this
procedure until the axle is out of the sprocket [C].
CD08867
Remove the axle sprocket from the chaincase [D]. D
P02101
742B, 743B Loader

AXLE, SPROCKET AND BEARINGS (Contd)
A
Remove the inner bearing from the chaincase [A].
Installation: Pack the outer and inner bearings with
grease before installing them.
P02107
If the other side axle, sprocket and bearings are removed

with one axle removed, use spacer plates and the
B
PortaPower ram [B].
P02105
Install the bearing cup puller tool into the axle tube [C].
C
B07627
Pull the bearing cup from the axle tube [D].

D
B07686
742B, 743B Loader

A
Use a long rod and bearing cup tool to remove the inner
bearing cup [A].
B07687
Use the correct size driver, install the outer bearing cup
[B].
B
B07679
Install the long threaded rod into the axle tube. Install the
correct size bearing cup driver tool. Install the washer and
C
nut [C].
B07680
Inside the chaincase, install the bearing cup driver tool,

washer and nut [D]. D
B07681
742B, 743B Loader

A
Hold the nut inside the chaincase [A].
B07683
Turn the nut on the outside of the axle tube until the inner
bearing cup is on its seat [B]. B
B07682
Use a press to remove the bearing from the axle [C]. C

Turn the axle around and press the new bearing into
position on the axle [C].
B07691 B07692
742B, 743B Loader

Added Sept. 93 417 Service Manual
DRIVE CHAIN
A
procedure:
MEL1242 PortaPower
MEL1037 Chain Link Tool
Section 1.)
Raise the operator cab. (See PREVENTIVE P02091
Remove the front panel/steering lever assembly. (See
B
Remove the parking brake/cover assembly. (See Page
42.)
Remove the hydrostatic pump. (See HYDROSTATIC
SYSTEM Section 3.)
Remove the front and rear cover.
Remove the fluid from the chaincase. (See Page 419.)
Remove the front axle sprocket bolt [A].
Installation: Tighten the axle sprocket bolt to 220245 P02092
Install a PortaPower ram between the two sprockets

C
[B].
Push the axle out until the ram is at the end of the stroke.
Add a spacer and repeat the procedure until the axle is out
of the sprocket.
Remove the motor carrier. (See Page 49.)
Remove the front and rear drive chain from the chaincase
[C].
P02109
Installation: If a new chain is installed, a connector link

must be used to connect the chain together. D
Use a chain link tool and #80 chain adapter.
Use a large wrench to hold the tool while pressing the
chain link.
Tighten the chain link tool bolt to 180 ft.lbs. (244 Nm)
torque to press the chain link onto the chain [D].
B13504
742B, 743B Loader

CHAINCASE FLUID
Replacing The Chaincase Fluid
A
Remove the chaincase cover and/or brake assembly.
(See Page 44.)
Use a transfer pump to remove the fluid from the
chaincase [A].
B05202
Use clean rags to remove any fluid that the pump did not
remove and clean the chaincase [B].
B
Use only recommended replacement fluid. Clark Bobcat
Fluid (P/N 6563328) or 10W30 or 10W40 Class SE
Motor Oil to fill the chaincase with 9 gals. (34 L.) fluid.
Install the transmission cover(s).
Lower the operator cab.
B03988
742B, 743B Loader

MAIN FRAME
Page
Number
BOBTACH
BobTach Lever And Wedge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 511
FUEL TANK
Fuel Level Sender Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 516
LIFT ARMS
OPERATOR CAB
OPERATOR CAB GAS CYLINDER
REAR DOOR
Door Latch Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 MAIN
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 FRAME
REAR GRILL

742B, 743B Loader

Service Manual
OPERATOR CAB
A
Remove the stop blocks at the rear of the operator cab
[A].
B09780
After the stop blocks are removed and the
operator cab has a rear window, REMOVE THE
REAR WINDOW to prevent damage to the rear
window. I21200297
B
Disconnect the wiring harness connectors [B].
CD12854
Remove the electrical clamp at the harness [C].

C
CD12855
Install a bar at the balance point of the operator cab.

Install a chain hoist [D]. D
B09782
742B, 743B Loader

51 Service Manual
OPERATOR CAB (Contd)
A
At the gas cylinder upper pin, remove the retainer clip
(both sides) [A].
B08511
Remove the upper pin from the gas cylinder (both sides)
[B]. B
Installation: Install the lower pivot pin first, use a
screwdriver to hold the gas cylinder and install the top
pivot pin [B].
B08510
Remove the retainer clip at the lower pivot pin (both sides)
[C]. C
B09889
Remove the lower pivot pin (both sides) [D].

D
B09890
742B, 743B Loader

52 Service Manual
OPERATOR CAB (Contd)
A
Remove the gas cylinder (both sides) [A].
B08509
Remove the nuts from the pivot bolts [B].

Installation: Tighten the pivot bolts to 2535 ft.lbs.
B
(3447 Nm) torque.
B09783
Use a punch to remove the pivot bolt (both sides) [C].

Lift the operator cab from the loader using the chain hoist.
C
B08539
742B, 743B Loader

53 Service Manual
OPERATOR CAB GAS CYLINDER
A
Remove the stop blocks at the rear of the operator cab
[A].
B09780
Remove the retainer clip at the upper pivot pin [B]. B

Remove the upper pivot pin [B].
B08511 B08510
Remove the retainer clip at the lower pivot pin [C].

C
Remove the lower pivot pin [C].
Installation: Install the lower pivot pin first, use a
screwdriver to hold the gas cylinder and install the top
pivot pin.
B09889 B09890
Remove the gas cylinder from the loader [D]. D
B08509
742B, 743B Loader

54 Service Manual
REAR DOOR
A
Door Latch Adjustment
Loosen the set screw [A].
B05772
Loosen the nut (Item 1) [B].

Turn the bolt (Item 2) [B] in or out, until the door contacts
B
both the top and bottom of the loader frame (Item 1) [C]
with the lever in the latched position.
NOTE: It takes approximately 50 lbs. of force to push

the lever down when the latch is adjusted
correctly.
2
1
B07385
With the set screw up, the flanges at the bolt (Item 2) [C]
must be to the sides so that the set screw aligns with the C 2
flat surface at the end of the bolt [C].
Tighten the set screw [A].
1
Tighten the nut (Item 1) [B] to 6570 ft.lbs. (8895 Nm)
torque.
B07226
1
B04099
742B, 743B Loader

55 Service Manual
REAR DOOR (Contd)
A
Install a chain hoist on the rear door [A].
B04568
Use a punch and hammer, remove both hinge pins [B]. B

Lift the door from the loader frame.
B04131
742B, 743B Loader

56 Service Manual
REAR GRILL
A
Remove the bolts along the top edge of the rear grill [A].
P00179
Remove the bolts along the bottom of the rear grill [B]. B
P00182
Lift the rear grill up and away from the loader [C].
C
P00184
742B, 743B Loader

57 Service Manual
BOBTACH
A
Tilt the BobTach fully forward until the front edge is on
the floor [A].
Stop the engine. Move the hydraulic controls to release
CD08942
Remove the retainer bolt from the pivot pin [B]. B

Installation: Tighten the retainer bolt to 1820 ft.lbs.
(2427 Nm) torque.
CD08709
Remove the grease fitting from the pivot pin [C]. C
CD08889
Use a punch and hammer, remove the tilt cylinder rod end D
pivot pin [D].
CD08710
742B, 743B Loader

58 Service Manual
BOBTACH (Contd)
A
Remove the hydraulic cylinder rod end. Remove the seals
[A].
CD08713
Installation: Put a piece of shim stock on each side over

the seals. Install the rod end into the BobTach frame [B].
B
CD08714
Remove the grease fitting from the BobTach frame for

the pivot pin (both sides) [C]. C
NOTE: The grease fitting at the pivot pin must be
removed because the grease can cause a
lock and the pivot pin can not be pushed into
the BobTach frame.
CD08890
Loosen the bolt at the BobTach pivot pin (both sides) [D].
D
Installation: Tighten the bolt to 130140 ft.lbs.
(176190 Nm) torque.
CD08891
742B, 743B Loader

59 Service Manual
BOBTACH (Contd)
A
Hit the bolt to start the pivot pin into the BobTach frame
(both sides) [A].
Remove the bolt. Use a punch to push the pivot pin all the
way into the BobTach frame.
Installation: A long bolt may be needed to turn into the
pivot pin. Pull the pivot pin into the lift arms.
Remove the BobTach frame from the lift arms.
CD08892
Remove the seal dust cup (both sides) [B]. B
CD08893
Remove the rubber seal (both sides) [C].

C
CD08894
Turn the bolt into the pivot pin. Remove the pivot pin from D
the BobTach frame [D].
Check for wear and damage. Replace the pivot pins as
needed.
CD08895
742B, 743B Loader

510 Service Manual
BOBTACH (Contd)
A
BobTach Lever And Wedge
Use the following procedure to remove and install the
BobTach lever, spring and wedge:
Remove the nut from the BobTach lever [A].
Installation: Tighten the nut to 2528 ft.lbs. (3438 Nm)
torque.
CD08896
Remove the bushing and spring [B]. B
CD08897
Remove the BobTach lever [C]. C
CD08898
Use a punch and hammer, remove the roll pin from the
BobTach wedge and spring bolt clevis assembly [D]. D
CD08899
742B, 743B Loader

511 Service Manual
BOBTACH (Contd)
BobTach Lever And Wedge (Contd)
A
Remove the spring, bolt and clevis assembly [A].
CD08900
If the spring is damaged, put the assembly in the vise and

remove the bolt [B]. B
Replace the worn or damaged parts as needed.
CD08901
Remove the wedge from the BobTach frame [C].

C
Always replace bent or broken wedges.
CD08902
742B, 743B Loader

512 Service Manual
LIFT ARMS
A
Roll the BobTach frame fully forward.
Remove the BobTach frame. (See Page 58.)
Fasten chains and chain hoist to the lift arms [A].
B02801
Put a floor jack under the lift arms [B]. B

Raise the lift arms, with the floor jack, until the pivot pin
at the rod end of the lift cylinder can be removed.
B04543
Remove the lock nut and bolt [C]. C

(2427 Nm) torque.
B09795
Remove the pins at the rod end of the lift cylinder (both
sides) [D].
D
Lower the lift arms. Remove the floor jack.
B09794
742B, 743B Loader

513 Service Manual
LIFT ARMS (Contd)
A
Remove the lock nut and bolt [A].
(2427 Nm) torque.
Tighten the chain hoist.
B04544
Use a punch and soft hammer, remove the pivot pin at the
lift arm (both sides) [B]
B
Raise the lift arms with the chain hoist and remove them
from the loader frame.
B04545
742B, 743B Loader

514 Service Manual
FUEL TANK
A
Use a transfer pump to remove the fuel from the fuel tank.
Remove the harness plate over and above the hydraulic
reservoir.
CD06271
Disconnect the wires at the fuel sender [B]. B
CD06272
Remove the fuel hoses from the tank fittings [C]. C
CD06273
Remove the fuel hoses at the shutoff valve [D].

D
CD06274
742B, 743B Loader

515 Service Manual
FUEL TANK (Contd)
742B(S/N509418001&Above),743B(S/N509318001&Above)ServiceManual#6720772MainFrameSection
A
Remove the fuel tank holding strap bolt [A].
Remove the fuel tank from the loader.
CD06275
Fuel Tank Sender Switch B

Remove the harness plate from the top of the fuel tank
[B].
Remove the wires from the sender.
CD06271
Remove the screws from the sender [C].

C
B12340
Remove the sender switch from the fuel tank [D].

D
B12341
742B, 743B Loader

516 Service Manual
ELECTRICAL SYSTEM
Page
Number
ALTERNATOR
Alternator Output Test (New Style) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Alternator Regulator Test (New Style) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Checking The Alternator Output (Old Style) . . . . . . . . . . . . . . . . . . . . . . . 64
Checking The Alternator Regulator (Old Style) . . . . . . . . . . . . . . . . . . . . 65
Disassembly And Assembly (New Style) . . . . . . . . . . . . . . . . . . . . . . . . . 612
Disassembly And Assembly (Old Style) . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Rectifier Continuity (Diode) Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 613
Rectifier (Diode) Test (New Style) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Removal And Installation (743B) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Rotor Continuity Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 613
Rotor Ground Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 613
Stator Continuity Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 612
Stator Ground Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 612
ALTERNATOR BELT SHIELD (743B)

BATTERY
Checking The Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
ELECTRICAL SYSTEM INFORMATION

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 ELECTRICAL
SYSTEM
STARTER
Checking The Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 615
Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 617
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 617
Replacing The Brushes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 619
Cleaning And Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 620
TROUBLESHOOTING
Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

742B, 743B Loader

61 Service Manual
ELECTRICAL SYSTEM INFORMATION
Description
The loader has a 12 volt, negative ground electrical
system. There are two main circuits.
1. The charging circuit has an alternator (with builtin Instructions are necessary before operating or
regulator) and a battery. servicing machine. Read Operation &
Maintenance Manual, Handbook and signs
(decals) on machine. Follow warnings and
2. The starting circuit has glow plugs, starter motor and instructions in the manuals when making
solenoid for starting the engine. repairs, adjustments or servicing. Check for
correct function after adjustments, repairs or
service. Failure to follow instructions can
Optional equipment for the loader are front and rear lights, cause injury or death [A].
windshield wiper, horn and backup alarm. W20030797
The electrical system is protected by two fuses installed

in the instrument panel. Fuses protect the electrical
system from an overload.
TROUBLESHOOTING
Chart
The following troubleshooting chart is provided for assistance in locating and correcting problems. Many of the
recommended procedures must be done by authorized Bobcat Service Personnel only.
PROBLEM CAUSE
Battery will not take a charge. 1, 2, 3, 4, 5

Alternator will not charge. 1, 2, 5
Starter will not turn the engine. 2, 3, 4, 6, 7, 8, 9
1. Alternator belt is loose or damaged.

2. Battery connections are dirty or loose.
3. Battery is damaged.
4. The ground connection is not making a good contact.

5. The alternator is damaged.
6. The engine is locked.
7. The starter is damaged.

8. The wiring or the solenoid is damaged.
9. Check the fuses.
742B, 743B Loader

61 Service Manual
BATTERY
A
Checking The Battery
procedure:
MEL10004 Battery Tester
To make a safe and complete check of the battery, see the
Battery Manual (P/N 6566047).
The Battery Manual has all the information needed for
checking and servicing the battery. Replace the battery as
needed.
P00183
B
Batteries contain acid which burns eyes and
skin on contact. Wear goggles, protective
clothing and rubber gloves to keep acid off
body.
In case of acid contact, wash immediately with
water. In case of eye contact get prompt medical
attention and wash eye with clean, cool water
for at least 15 minutes.
If electrolyte is taken internally drink large
quantities of water or milk! DO NOT induce
vomiting. Get prompt medical attention. P00186
W20651296
DO NOT remove the vent caps from the battery while

charging the battery. The battery vent caps will decrease
the possibility of battery being exploded by an external
spark.

Disconnect the negative () cable first.
Disconnect the positive (+) cable [A].
Remove the nuts and bolts from the holddown clamp [B].
Remove the holddown clamp.
Remove the battery from the loader.
742B, 743B Loader

62 Service Manual
ALTERNATOR BELT SHIELD (743B)
A
Disconnect the negative () battery cable.
Remove the bolt at the timing case cover [A].,
P00247
Remove the bolt at the bottom of the alternator mounting

bracket [B]. B
P00248
Remove the bolt from the thermostat housing [C].

C
P00207
Remove the belt shield [D].

D
P00206
742B, 743B Loader

ALTERNATOR
A REAR VIEW OF ALTERNTOR
Checking The Alternator Output (Old Style) OLD 6632211

death.
W20170286 MC01813

MAINTENANCE Section 1.) B
Disconnect the negative () cable from the battery.
Disconnect the orange wire (Item 1) [B] from the
alternator. Connect that wire to the negative () side of the
ammeter.
Connect the positive (+) side of the ammeter to the output
terminal on the alternator (Item 2) [B].
1
Disconnect the fuel shutoff valve.
Connect the negative () cable to the battery. 2
Turn on the lights and crank the engine for 30 seconds to

discharge the battery.
Open the fuel shutoff valve.
Start the engine and run at 2600 RPM.
CD06325
The ammeter reading should be between 4555 amps. @
2600 RPM.
If the reading is low, remove the screws and pull the C
regulator cover away from the alternator.
Disconnect the battery and connect a jumper wire from

the alternator output terminal (Item 1) [C] to the regulator
terminal (Item 2) [C].
Connect the battery cable, start the engine and check the 1
ammeter. If the reading is within the rated amperage 2
(4555 amps. @ 2600 RPM) replace the diode trio.
B09570
742B, 743B Loader

ALTERNATOR (Contd)
A
Checking The Alternator Regulator (Old Style)
(Contd)
Connect the positive (+) voltmeter lead to the positive (+)
battery terminal and connect the negative () voltmeter
lead to the negative () terminal [A].

death.
W20170286 B03710
B08068

gases which can kill without warning. 1
W20501285
2
Start and run the engine at 15002000 RPM. The

voltmeter reading should be between 13.914.7 volts [A].
If the reading is low, stop the engine and disconnect the
battery.
B09569
Remove the screws and pull the regulator cover away
from the alternator. Connect the jumper wire from the
ground stud (Item 1) [B] to the brush terminal (Item 2) [B]
(the tan wire).
Connect the battery and start the engine. Run at 1500
RPM. DO NOT allow the meter to exceed 16 volts.
If the reading is 14.5 or above, replace the regulator.
If the reading is 14.5 or below, repair or replace the
alternator.
742B, 743B Loader

ALTERNATOR (Contd)
A REAR VIEW OF ALTERNTOR
Test the New Style alternator as follows: New 6661611
a. Alternator Output Test
b. Rectifier (Diode) Test
c. Alternator Regulator Test
Alternator Output Test (New Style)
Put jackstands under the front axles and rear MC01813

death.
B 2
W20170286

Disconnect the red wire (Item 1) [B] from the alternator.
Connect that wire to the negative () side of the ammeter.
Connect the positive (+) side of the ammeter to the output
terminal on the alternator (Item 2) [B].
P01360
Disconnect the fuel stop solenoid connector.
Connect the negative () cable to the battery.
C Output
Terminal
Turn on the lights and crank the engine for 30 seconds to
discharge the battery.
Connect the fuel stop solenoid, start the engine and run
at 2600 RPM.
The ammeter reading should be between 4555 amps. at
2600 RPM. 1
If the reading is low, remove the screws and pull the

regulator cover away from the alternator.
Regulator
Rectifier (Diode) Test (New Style) Terminal
P01304
The alternator is removed from the loader for clarity
purposes [C].
Install the wires in their original location on the back of the
alternator.
Connect a jumper wire (Item 1) [C] to the alternator output
terminal and the regulator terminal.
Connect the battery negative () cable.
Start the engine and run at 2600 RPM.
If the reading is within 4555 amps. at 2600 RPM replace
the rectifier (diode) assembly or replace the alternator.
If the reading is low, do the Alternator Regulator Test.
742B, 743B Loader
ALTERNATOR (Contd)
A
Alternator Regulator Test (New Style)
Negative

concentration of exhaust fumes. If the engine Positive
gases which can kill without warning. P01308
W20501285
Connect the positive (+) voltmeter lead to the positive (+)

battery terminal [A].
B
Connect the negative () voltmeter lead to the negative
() battery terminal [A].
Ground
Start the engine and run at 15002000 RPM. Stud
The voltmeter should read between 13.914.7 volts.
If the reading is low stop the engine and disconnect the Brush
battery negative () cable. Terminal
1
The alternator is removed from the loader for clarity
purposes [B].
P01364
Remove the wires from the back of the alternator.
Remove the regulator cover from the back of the
alternator.
Install the wires on the back of the alternator.
Connect a jumper wire (Item 1) [B] from the brush
terminal to the ground stud.
Connect the negative () battery cable and start the
engine. Run at 1500 RPM.
If the voltmeter reading is 14.5 or above replace the
regulator.
If the voltmeter reading is below 14.5, repair or replace the
alternator.
742B, 743B Loader

ALTERNATOR (Contd)
A
Removal And Installation (743B)
Remove belt shield. (See Page 63.)
Disconnect the negative () cable from battery.
Disconnect the wires from the back of the alternator.
Remove the adjusting bolt [A].
P00211
Remove the mounting bolt and nut [B].

Remove the alternator.
B
AVOID INJURY OR DEATH

Never service or adjust the machine when the
engine is running unless instructed to do so
in the manual.
W20120497
P00210

C
Remove the belt Shield. (See ENGINE SERVICE Section
7.)
Disconnect the negative () cable at the battery.
Disconnect the alternator connector from the electrical
harness [C].
Disconnect the orange lead at the alternator.
B09881
Remove the adjusting bolt [D]. D

Remove the mounting bolt [D].
Remove the alternator from the mounting bracket.
B09939
742B, 743B Loader

ALTERNATOR (Contd)
Disassembly And Assembly (Old Style)
A
1
Disassemble the alternator as shown in figure [A].
2 3
Remove the three bolts (Item 4) [A] holding halves 9
together. 6
7
16
Pry the halves apart. 5 6
4 8
Use a soft jaw vise to hold the rotor while removing the
pulley nut (Item 1) [A].
Remove the front case half (Item 5) [A] from the rotor
using a plastic hammer or press.
Unsolder the stator wires from the rectifier to test the
stator and rectifier. Use a needle nose plier to remove the
wires. 13
10 11 12
15
14
1. Nut
2. Pulley
3. Fan
4. Bolt
5. Case Half (Front)
6. Bearing 11. Heat Sing ()
7. Rotor 12. Case Half (Rear)
8. Slip Ring 13. Condenser Assy.
9. Stator 14. Brush Holder
10. Heat Sink (+) 15. Regulator D01760
Use the following procedures with an ohmmeter to test

the rotor: B
Touch both probes on the slip rings. There must be a 3 to
5 ohm reading [B].
B09375
Touch one probe to the shaft and one probe to a slip ring,
then touch the other slip ring. There must be maximum C
resistance [C].
B09376
742B, 743B Loader

ALTERNATOR (Contd)
Disassembly And Assembly (Old Style) (Contd)
A
Use the following procedure with an ohmmeter to test the
stator:
Touch two wire ends of the stator with the probes, take a
reading. Move one probe to the other wire. The reading
should be the same [A].
B09380
Test the ground by touching one probe on the metal

surface of the stator and the other probe on the bare wire.
There must be no needle movement [B].
B
B09378
Use the following procedure with a circuit tester to test the

rectifier:
C
Touch the positive probe to the positive diode holder and
the negative probe to each diode terminal. There must be
continuity [C].
B09377
Reverse the probes and check the continuity in the other

direction. There must be no continuity. D
B09385
742B, 743B Loader

ALTERNATOR (Contd)
Disassembly And Assembly (Old Style) (Contd)
A
Touch the negative probe to the negative diode holder and
the positive probe to each diode terminal. There must be
continuity [A].
B09377
Reverse the probe and check the continuity in the other

direction. There must be no continuity [B]. B
Check the brushes for wear. The maximum of exposed
brushes should be 0.125 inch (3,0 mm).
Replace broken or rusted brush springs.
B09385
Assembly:
C
Reverse the order of disassembly.
Place the rotor in soft jaws when tightening the shaft nut.
Tighten to 50 ft.lbs. (68 Nm) torque [C].
B09383
742B, 743B Loader

ALTERNATOR (Contd)
Disassembly and Assembly (New Style)
A
1
Disassemble the alternator as shown [A].
2 3
Remove the regulator cover and regulator. 9
6
7
Remove the four bolts holding halves together. 16
5 6
4 8
Pry the halves apart (use a press if needed).
Use a soft jaw vise to hold rotor while removing pulley nut.
Remove front case half from the rotor using a plastic
hammer or press.
Unsolder the stator leads from the rectifier. Remove the
stator.
13
10 11 12
15
14
1. Nut
2. Pulley
3. Fan
4. Bolt
5. Case Half (Front)
6. Bearing 11. Heat Sing ()
7. Rotor 12. Case Half (Rear)
8. Slip Ring 13. Condenser Assy.
9. Stator 14. Brush Holder
10. Heat Sink (+) 15. Regulator D01760
Stator Continuity Test

B
Use an ohmmeter to test the stator.
Touch the probes to two of the bare stator wires [B].
Move one of the probes to the third wire.
The readings should be the same.
If there is no continuity, replace the stator.
P01369
Stator Ground Test

C
Touch one probe to a bare stator lead and the other probe
to the bare metal surface of the stator [C].
There should be no continuity.
Replace the stator if there is continuity.
P01386
742B, 743B Loader

ALTERNATOR (Contd)
A
Rotor Continuity Test
Touch the probes to the slip rings [A].
The ohmmeter should read between 3.06533.85 ohms.
If there is no continuity replace the rotor.
P01365
Rotor Ground Test

Touch one probe to one of the slip rings and the other
B
probe to the rotor shaft [B].
There should be no continuity.
Replace the rotor if there is continuity.
P01378
Rectifier Continuity (Diode) Test
NOTE: In the diode tests there should be continuity

C
in one direction only. If the diode being
tested shows no continuity or continuity in
both directions, replace the rectifier
assembly.
Touch the probes to the terminals of each diode and read
the meter [C].
Reverse the probes to check the diode in the other
direction.
There should be continuity in one direction only.
P01373
Touch one probe to the diode and the other probe to the
connected heatsink and read the meter [D]. D
direction.
Touch on Bottom
Heat Sink
P01370
742B, 743B Loader

ALTERNATOR (Contd)
Rectifier Continuity (Diode) Test (New Style) (Contd)
A
Touch one probe to the diode and the other probe to the
connected heatsink and read the meter [A].
direction.
Touch on Center
Heat Sink
P01390
Assembly (New Style) B

Reverse the order of disassembly.
Do not assemble the rear case half.
Place the rotor in soft jaws when tightening the shaft nut.
Tighten to 50 ft.lbs. (68 Nm) torque [B].
Install the rear case half and the remaining parts.
P01808
742B, 743B Loader

STARTER
A Jumper Wire
Checking The Starter
Bat
The key switch must be in the OFF position. S
M
The battery must be at full charge.
The cable connections on the battery must be clean and
tight.
Cranking
Connect a jumper wire between S terminal and BAT Motor
terminal [A].
If the starter turns but does not turn the engine, the starter
drive has a defect.
A01992
Connect a jumper wire between the M terminal and the

BAT terminal [B].
B Jumper Wire
Bat
If the starter turns, the defect is in the solenoid. S
If the starter does not turn, the starter is defective. M
Cranking
Motor
A01991

C
Mark the wires on the starter and solenoid. Disconnect
the wires [C].
P01180
Remove the stator mounting bolts [D].

D
Nm) torque.
Remove the starter.
P01182
742B, 743B Loader

STARTER (Contd)
A
Disconnect the negative () cable at the battery.
Disconnect the positive (+) cable at the starter solenoid
[A].
P09880
Disconnect all the wires at the starter solenoid [B].

B
B09879
Remove the two bolts at the starter heat shield [C].

C
B09937
Remove the starter mounting bolts [D].

Remove the starter from the engine. D
B09936
742B, 743B Loader

STARTER (Contd)
Parts Identification
1 Screw
2. Solenoid
3. Bolt
4. Lever
3 5. Washer
2 6. Nut
4 7. Plug
8. Washer
9. Housing Drive
1 10. Washer
11. Bushing
12. Ring
5 13. Stop
14. Drive
15. Drive Support
16. Support
6 17. Drive Shaft
9 7 18. Washer
19. Washer
8 20. Washer
21. Screw
19 22. Brush
23. Frame Assy.
24. Gasket
25. Pin
26. Armature Support
10 13 17 27. Bolt
18 20 28. Spacer
12 14 16
15 29. Bearing
30. Armature
31. Bearing
11 32. Spring
33. Holder Assy.
21 34. Brush
22 35. Screw
26
25 24 36. Oring
37. Frame
38. Washer
39. Screw
40. Bolt
23
27 22
21
35
30 34 39
28 29 31 34 38
32
33 36 37 40
D02119
742B, 743B Loader

STARTER (Contd)
Disassembly And Assembly
A
Remove the starter thrubolts [A].
CD08924
Remove the screws for the brush holders [B].

B
CD08925
Remove the starter end cap [C].

C
CD08926
Remove the starter housing/armature assembly from the

reduction gear drive [D].
D
CD08927
742B, 743B Loader

STARTER (Contd)
A
Disassembly And Assembly (Contd)
Remove the armature and brushes from the starter
housing [A].
CD08928
Remove the bolts from the reduction gear housing [B].

B
CD08929
Remove the reduction gear housing [C].

C
CD08930
Replacing The Brushes

Remove the screws at the brushes [D]. D
Remove the screws at the brush leads.
Remove the old brushes.
Install the new brushes and make sure to tighten the
screws.
Assembly of the starter: Reverse the order of
disassembly. Put a small amount of grease on the splines
of the armature and the bushings. Add or remove shims
at the drive end of the armature to adjust the end play.
B09940
742B, 743B Loader

STARTER (Contd)
742B(S/N509418001&Above),743B(S/N509318001&Above)ServiceManual#6720772ElectricalSystemSection
Cleaning and Inspection

A
Use a brush and air pressure to clean the drive, field coils,
armature and starter housing.
NOTE: Do not use solvent to clean the drive

assembly. The solvent will remove the
lubricant and the drive will slip.
Check the following items:

Armature
Broken or burned insulation.
Loose connections at commutator. A01995
Open or grounded circuits [C] & [D].
Worn shaft or bearings.
Rough commutator.
Brush Holders
B
Broken springs.
Broken insulation.
Spring tension.
Field Coils
Broken or burned insulation.
Electrical continuity.
Brush connections.
Drive Gears
Worn teeth.
Tooth engagement.
A01994
Field Coils
Broken or burned insulation
Electrical continuity [C]. C
Brush connections.
B02122
Drive Gear:
Worn teeth
Tooth engagement (drive gear must engage ring gear
D
by 1/2 the depth of the ring gear tooth)
To test for ground, use a test light and touch one probe to
the body and the other probe to the field winding end of
the brush. The lamp should not light [D].
B09576
742B, 743B Loader

ENGINE SERVICE
Page
Number
KUBOTA ENGINE (742B) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A1
MITSUBISHI ENGINE (742B) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B1
ENGINE
SERVICE
KUBOTA
(743B)
MITSUBISHI
(742B)
742B, 743B Loader

7A3 Service Manual
ENGINE SERVICE (Contd)
(Kubota 743B)
Page
Number
BLOWER HOUSING
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A11
CYLINDER HEAD
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A19
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A15
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A19
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A14
Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A15
Valve Guide Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A17
ENGINE
ENGINE ASSEMBLY
Crankshaft Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A33
Gearcase Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A35
Installing The Camshaft And Timing Gears . . . . . . . . . . . . . . . . . . . . . 7A33
Installing The Pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A33
ENGINE COMPRESSION
Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A3
ENGINE FLYWHEEL AND UJOINT
Flywheel Ring Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A12
ENGINE REPAIR
Crankshaft Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A28
Cylinder Liner Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A29
Gearcase Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A20
Lubrication System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A30
Oil Pump Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A31
Piston and Crankshaft Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A23
Servicing The Connecting Rods And Pistons . . . . . . . . . . . . . . . . . . . . 7A26
Timing Gear, Camshaft And Oil Pump Removal . . . . . . . . . . . . . . . . . 7A22
Timing Gear And Camshaft Service . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A25
Water Pump Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A31
KUBOTA
FUEL FILTER (743B)
Removing Air From The Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . 7A2
Replacing The Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A2
FUEL INJECTION PUMP
Checking The Injection Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A5
Timing The Injection Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A4
FUEL INJECTION NOZZLES
Checking the Nozzles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A7
GLOW PLUGS
Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A2
MUFFLER
RADIATOR AND OIL COOLER
TROUBLESHOOTING
Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A1
742B, 743B Loader

7A1 Service Manual
TROUBLESHOOTING
Chart
The following troubleshooting chart is provided for assistance in locating and correcting problems which are most common.
Many of the recommended procedures must be done by authorized Bobcat Service Personnel only.
PROBLEM CAUSE
Engine will not turn over with the starter. 1, 2, 3, 4, 5, 6

Engine will not start or is difficult to start. 7, 8, 9, 10, 11, 12, 13,
14, 15, 15, 17, 18, 19
Engine misses, runs irregularly or stops. 20, 21, 22, 23, 24
Engine overheats. 25, 26, 27, 28

To much engine vibration. 29, 30

1. Battery has lost its charge.
2. Loose battery connections.
3. Loose starter connections.
4. Damaged starter switch.
5. Broken starter switch.
6. Damaged starter solenoid.
7. Wrong starting procedure.
8. No fuel in tank.
9. Air cleaner is dirty.
10. Fuel vent in cap has restricted.
11. Fuel line has air leak, dirt or water.
12. Damaged fuel lift pump.
13. Hydraulic/Hydrostatic load on engine.
14. Damage to fuel injection system
15. Crankcase oil is thick.
16. Check glow plugs.
17. Check preheat solenoid.
18. Check the fuel shutoff button.
19. Delivery valve nuts not tightened.
20. Fuel injection set wrong.
21. Dirty fuel, or fuel filter restricted.
22. Poor compression.
23. Wrong fuel.
24. Water in the fuel
25. Engine is overloaded.
26. Dirty engine oil.
27. Exhaust system has restriction.
28. Injection timing is wrong.
29. Loose engine mounts.
30. Worn rubber mounts.
742B, 743B Loader

7A1 Service Manual
FUEL FILTER
Replacing The Fuel Filter
A 3
2
See SERVICE SCHEDULE Page 11 for correct service
intervals.
1
To replace the fuel filter element:
Clean the filter areas.
Shutoff the fuel at the fuel tank.
Remove the bolt from the top of the filter housing (Item 1)
[A].
Remove the element and the rubber seal from the B03916
housing.
Install a new rubber seal on the housing and put a small
amount of oil on the rubber seal.
B
Install the new filter element in the container and install on
the filter head. Hand tighten only.
Open the fuel shutoff valve at the tank until the fuel filter
container is full.
1
Tighten the bolt to prevent leakage.
Removing Air From The Fuel System
After replacing of the fuel filter element or when the fuel
tank has run out of fuel, the air must be removed from the
fuel system before starting the engine. P00217
Open the rear door. The engine must be cool.

Open the vent plug (Item 2) [A]. C
Operate the hand pump (Item 3) [A] until fuel flows from
the vent plug (Item 2) [A] with no air bubbles.
Tighten the vent plug.
Operate the hand pump until it feels solid.
Move the throttle control to minimum ROM. Loosen the
valve (Item 1) [B] and squeeze the hand pump several
times.
Start the engine. When the engine runs smoothly, close
the valve (Item 1) [B]. P01807
GLOW PLUGS
Checking
Disconnect the glow plug cables and leads.
Use an ohmmeter to check the glow plugs.
Touch one probe to the end of the glow plug and the other
probe to the body of glow plug [C].
The reading must be between 1 and 2. If the resistance
is zero ohms the glow plug has a short circuit. If the
resistance is infinite the coil of the flow plug is broken.
Repeat the procedure for each glow plug.
742B, 743B Loader

Revised Sept. 93 7A2 Service Manual
ENGINE COMPRESSION
A 3
Checking 2
The tool listed will needed to do the following procedure:
MEL1063 ENGINE COMPRESSION KIT
1
The engine must be warm. Disconnect the glow plug
wires. Remove the glow plugs.
4
Install the compression adapter in the glow plug hole.
Connect the compression gauge.
Run the engine with the starter. Do the compression test
at least twice.
B10779
The compression must be at least 75% of 427469 PSI
(29443233 kPa) with no more than 50 PSI (345 kPa)
difference between cylinders. B
FUEL INJECTION PUMP
1
The injection pump contains parts which have a very
close tolerance and its operation has a direct effect on the
performance of the engine.
Removal and Installation Delivery

Valve
Clean the area around the injection pump. Disconnect the Nuts
fuel shutoff linkage (Item 1) [A]
Disconnect the fuel inlet hoses (Item 2) [A].
Disconnect the high pressure tubelines (Item 3) [A]. B04111
Installation: Tighten the delivery valve nuts to 2936

Do not attempt to maintain or adjust unless

you are trained and have the correct
equipment.
I20280289
Do not bend the high pressure fuel injection
tubes when removing or installing them.
I20290289
Remove the side cover (Item 4) [A].

Remove the four mounting nuts.
Installation: Tighten the nuts to 1720 ft.lbs. (2327
Nm) torque.
Put the pin in the control rack in alignment with the slot in
the engine block (Item 1) [B]. Remove the injection pump.
NOTE: Make sure the same number of shims are

installed under the injection pump. The
shims are used for engine timing.
Installation: When the injection pump is installed, make
sure the pin (Item 2) [B] on the control rack is correctly
installed on the fork lever. If the slot is not installed
correctly, the engine will run over maximum speed and
serious damage can result.
742B, 743B Loader
Revised July 96 7A3 Service Manual
FUEL INJECTION PUMP (Contd)
A
Timing The Injection Pump
Timing of the fuel system is done by changing the number
of shims between the injection pump and the engine
block, The timing of the fuel injection pump will be later
when a shim is added, and earlier when a shim si
removed.
B03611
can penetrate skin or eyes, causing serious
not be visible. Use a piece of cardboard or wood B
familiar with this injury. 1
W20720496
Remove the number 1 cylinder injector tubeline from the

injector pump.
Install a short pipe to the outlet of the number 1 cylinder
injector port. Point the pipe up (vertical).
With a fuel supply to the injection pump, rotate the engine
in a clockwise direction. Fuel must flow from the pipe B11493
when the fixed mark F1 on the crankshaft pulley and the
point comes into alignment [A].
The correct timing for the engine is 25 degrees B.T.D.C.

(#1 cylinder). Add or subtract shims (Item 1) [B] as
needed to adjust the delivery time of the fuel. Each shim
will change the timing 1.5 degrees.
742B, 743B Loader

7A4 Service Manual
FUEL INJECTION PUMP (Contd)
Checking The Injection Pump
A
procedure: 1
MEL1237 Adapter Fuel Line
MEL11731 Pressure Gauge
To check the discharge pressure at the fuel injection
pump, use the following procedure:
Disconnect a high pressure fuel line (Item 1) [A] at the
pump. Loosen the other end of the same high pressure
line so it can be turned away from the fitting.
B09577
Connect the adapter fuel line (Item 1) [B] to the fitting.

Connect the pressure gauge (Item 2) [B].
B
Rotate the engine, with the starter, until the pressure
raises. Then turn the engine by hand until the pressure
gauge reads 1400 PSI (9653 kPa).
Align F1 on crankshaft pulley.
1
The injection pump must hold the 1400 PSI (9653 kPa) for
at least 5 seconds. If not, replace or repair the injection
pump.
2
B09578
742B, 743B Loader

7A5 Service Manual
FUEL INJECTOR NOZZLES
A

familiar with this injury. B11664
W20720496
Some problems caused by faulty injector nozzles:

B
The engine is hard to start or will not start. Rough engine
operation and idle. The engine will not have full power.
The engine exhaust smoke is black, white or blue.
procedure:
MEL1181 Nozzle Wrench
1
B11523
Do not bend the high pressure fuel injection

C
tubes when removing or installing them.
I20290289
Disconnect the high pressure fuel lines at the fuel injector

[A].
Disconnect the high pressure fuel lines at the injection

pump [B].
Remove the high pressure lines [C]. B11663
Disconnect the low pressure hoses (Item 1) [D] at the

injectors. D
Use the special tool and remove the fuel injector from the
cylinder head.
1
Installation: Tighten the delivery valve nuts (Item 1) [B]
to 2936 ft.lbs. (3949 Nm) torque.
Tighten the nozzle holder to 2236 ft.lbs. (3029 Nm) in
the cylinder head.
B11586
742B, 743B Loader

7A6 Service Manual
FUEL INJECTOR NOZZLES (Contd)
Checking the Nozzles
A
You can adjust the release pressure of the injector by
adding or removing spacers (Item 1) [A] at the top of the
nozzle spring (Item 2) [A].
Each 0.0039 inch (0,01 mm) spacer will change the
release pressure about 142 PSI (979 kPa). The release
pressure must be 19202133 PSI (1323814707 kPa).
Connect the injector nozzle to the tester with the nozzle 2
down.
1
Use tools MEL10018 & MEL10019.
B04103
Operate the hand lever at a slow rate and not the opening
pressure.
If the pressure is not correct, disassemble the injector
B Spring
nozzle and add or remove spacers. CORRECT WRONG
Pressure
Assemble the injector nozzle and check the pressure Pin
again. Holder
When you assemble the injector nozzle, tighten the Nozzle
nozzle body (Item 3) [A] to 4358 ft.lbs. (5979 Nm) Body
torque.
Needle
NOTE: Do not over tighten, or slow action of the Valve
valve will occur.
Check for inside leakage. Operate the hand lever until the A02621
pressure is almost enough to open the injector valve.
Record the pressure.
Release the hand lever. Check the pressure decrease for
10 seconds.
If the pressure decrease is more than 740 PSI (5102 kPa)
in 10 seconds, the nozzle is damaged.
Check that the spray pattern is correct [B].

The spray pattern is not correct if any of the following
occur: Do not disassemble or test the injector
nozzles unless you have the correct service
Fuel comes out of the side of the nozzle. and testing tools.
I21210297
Drops of fuel are present at the nozzle.
The nozzle does not have an even flow coming from the
nozzle.

W20720496
742B, 743B Loader

7A7 Service Manual
ENGINE
A
Open the rear door and clean the engine area.
Disconnect the battery cables, ground cable first.
Remove the coolant from the engine. The radiator cap
must be loosened to drain coolant. 1
Connect a hose to the valve or use a funnel to keep

coolant from getting into the engine compartment. Open
the valve (Item 1) [A] and drain coolant into a container.
Turn the lever (Item 1) [A] on the valve. When all the
coolant is removed close the valve. P00174
Close the shutoff valve. B

Remove the exhaust pipe from the manifold [B].
P01178
Remove the radiator hoses [C].

C
P01177
Remove the fuel return hose [D].

D
P01176
742B, 743B Loader

7A8 Service Manual
ENGINE (Contd)
A
Disconnect the battery cable and wires from the starter
[A].
Remove the bolts which mount the relays to the loader
frame.
Remove the fuel inlet line at the fuel filter.
P01180
Disconnect the air cleaner hose [B].

Disconnect the throttle linkage at the injector pump.
B
Disconnect the engine wiring harness from the operator
cab wiring harness.
P01179
Remove the engine mounting bolts [C]. C

Installation: Tighten the engine mounting bolts to 6570
P01181
Remove the engine from the loader [D].

Installation: Have a second person put their hand into D
the pump area. Align the coupler ujoint on the splined
shaft of the hydrostatic pump. If the splines do not match,
turn the engine with the crankshaft nut socket
(MEL1234). Slide the engine into the loader.
B04727
742B, 743B Loader

7A9 Service Manual
RADIATOR AND OIL COOLER
A
Remove the coolant from the cooling system.
Remove the panels from the blower housing [A].
Disconnect the overflow hose from the radiator.
Drain the coolant tank and remove the tank.
Disconnect the radiator hoses from the radiator.
P00187
Disconnect the tubeline from the oil cooler [B].

Disconnect the hose from the oil cooler.
B
B04762
Remove the radiator mounting bolts.

Installation: Tighten the bolts to 1516 ft.lbs. (2123 C
Nm) torque.
Remove the radiator/oil cooler assembly.
Remove the radiator mounting bolts (Item 1) [C].
Remove the radiator from the mounting frame.
1
Remove the oil cooler mounting bolt (Item 2) [C] and nuts.
Remove the oil cooler from the mounting brackets.
Installation: Fill the radiator with premixed coolant
(50% water and 50% antifreeze). Fill the coolant
recovery tank 1/3 full with premixed coolant.
E01500
E01591
742B, 743B Loader

7A10 Service Manual
BLOWER HOUSING
A
Remove the engine. (See Page 7A8.)
Remove the radiator, oil cooler assembly. (See Page
7A10.)
Disconnect the fuel lines from the fuel filter [A].
B04746
Remove the center nut from the blower housing [B]. B
B04760
Remove the bottom bolt from the blower housing [C].

C
B04747
Remove the blower housing [D].

D
B04748
742B, 743B Loader

7A11 Service Manual
A
Remove the engine. (See Page 7A8.)
Remove the four bolts at the ujoint mounting flange [A].
Installation: Put LOCTITE on the four bolts. Tighten the
bolts to 2528 ft.lbs. (4348 Nm) torque.
B08698
Remove the ujoint from the flywheel [B].

MEL1187 Socket
B
B08699
Bend the locking tabs away from the bolt flats [C].
Installation: Bend the locking tabs against the bolt flats. C
Remove the flywheel bolts [D].

C02673
Nm) torque.
D
Flywheel Ring Gear
The ring gear on the flywheel is an interference fit. Heat
the ring gear enough to expand it and hit it with a hammer,
evenly to remove it.
Clean the outer surface of the flywheel to give a smooth
fit.
Clean the new ring gear and heat it to a temperature of
450500F (232260C).
Fit the ring gear over the flywheel. Make sure the gear is
on its seat correctly. B04776
742B, 743B Loader

7A12 Service Manual
MUFFLER
A
Remove the exhaust pipe from the muffler [A].
B04775
Remove the bolts holding the muffler [B].

B
B04761
742B, 743B Loader

7A13 Service Manual
CYLINDER HEAD
A
Removal
Remove the nuts from the valve cover and remove the
valve cover [A].
C02559
Disconnect the injector tubelines. Remove the injector

nozzles and the copper gasket [B]. B
Remove the intake manifold.
Remove the belt shield and remove the alternator.
B04091
Remove the rocker arm [C].

Remove the push rods.
C
Remove the water return pipe.
Remove the cylinder head bolts.
A02764
Remove the cylinder head [D].

Remove the cylinder head gasket and the Orings. D
B04120
742B, 743B Loader

7A14 Service Manual
CYLINDER HEAD (Contd)
A
Disassembly
NOTE: There may be a shim under the head gasket.

Use the shim over again or replace it with the
same size shim.
Remove the valve cap (Item 1) [A] and the valve spring
collet (Item 2) [A].
Remove the valve spring retainer (Item 3) [A]. 1 2 3
4 6 5
Remove the spring (Item 4) [A]. Cap Collets Retainer Spring Valve Seal
Remove the seal (Item 5) [A] and the valve (Item 6) [A]. B04122
Remove the thermostat [B].

B
B03643
Servicing
C 1
Use the tool listed for the following procedure:
MEL1098 Valve Lapper
Clean the surface of the cylinder head.
Put a straight edge (Item 1) [C] on the cylinder head.
NOTE: Do not put the straight edge across the
combustion chamber. 2
Put a feeler gauge (Item 2) [C] between the straight edge

and the surface of the cylinder head.
A02735
The maximum distortion of the cylinder head surface is
0.002 inch ( 0,005 mm).
If the measurement is more than the specifications, the
D
cylinder head must be planed.
NOTE: Place a soft brass rod through the injector

hole and tap the combustion chamber out
before planing the head. Plane the same
amount from the bottom side of the
combustion chamber before installing it
back in the head.
Clean the valve surface.
Measure the width of the valve seat [D].
B03632
742B, 743B Loader

7A15 Service Manual
Servicing (Contd)
A A C Valve Contacting
Width
B
The correct width of the valve seat is 0.0827 inch (2,1
mm) and the seat angle is 45 degrees.
Grind the valve seats as follows:
Corrected
Use a 45 cutter to grind the surface of the valve seat [A]. Surface of
Uncorrected Valve Seat
Use a 15 cutter to grind the front surface of the valve seat Surface of
[A]. Valve Seat
Use a 65 or 75 cutter to grind the rear surface of the A 45 cutter
valve seat to finish the seat to a 0.0827 inch (2,1 mm) B 15 cutter
width [A]. C 65 or 70 cutter A02729
Grind the valve surface to a 45 angle.

B
Install the valve in the seat and check the depth [B].
The specifications for the depth of the valve is
0.04330.0512 inch (1,091,30 mm).
If the measurement is more than the specification, add
the correct thickness of the washer under the valve spring
to keep the correct tension on the spring.
Clean the valve guide.
Install the valve in the cylinder head.
Install the dial indicator. B03634
Measure the clearance of the valve guide and the valve

[C]. C
The measurement must be 0.00160.0023 inch
(0,040,06 mm).
If the measurement exceeds the limit, replace the valve
guide. (See Page 7A21 for valve guide installation.)
Ream the new guide to the correct dimensions.
Measure the valve spring. The length of the spring must
be 1.64171.6614 inch (41,742,2 mm).
Replace the valve spring if it does not meet these
specifications. B03698
Check the valve spring with a combination square to

make sure it stands straight.
D
Replace it if is not straight [D].
B03680
742B, 743B Loader

7A16 Service Manual
A
Servicing (Contd)
Put the valve spring in a tester [A].
Push down on the spring 1.3839 inch (35,15 mm). The
compression load must be 22.526.5 lbs. (100118 N).
Replace the valve spring if it does not meet these
specifications.
A02759
Measure the inside diameter of the rocker arm bushing

(Item 1) [B] and the shaft diameter (Item 2) [B]. B
The inside of the rocker bushing is 0.55130.5529 inch
(14,014,04 mm).
If the measurements are not within the specifications
replace the needed parts.
B03697
Valve Guide Installation 1.600

Use the tools listed to replace the valve guides:
C (40,6 mm)
8.000
Pressfit tool (203,2 mm)
Auxiliary fitting 3.150
Margin adjustment jig (80 mm)
See figure [C] for dimensions to make the pressfit tool.
0.510 0.303
80.800 12,95 mm) (7,7 mm)
(20,3 mm)
MC01389
See figure [D] for dimensions to make the auxiliary fitting.

D
0.590
(14,99 mm)
R 0.155
(3,9 mm)
0.200
Auxiliary (5,08 mm)
Fitting
MC01390
742B, 743B Loader

7A17 Service Manual
Valve Guide Installation (Contd)
A
See figure [A] for dimensions to make the margin
adjustment jig. Margin
Adjustment 0.700 R 0.260
Jig (17,8 mm) (6,6 mm)
0.394
(10,0 mm)
MC01390
Use the following procedure to replace exhaust (Item 1)

[B] and inlet (Item 2) [B] valve guides. B
Remove the cylinder head. (See Page 7A14.)
Ream the new valve guide to the correct dimensions.
Use the pressfit tool to remove the old valve guide from 1
Exhaust Valve Guide
the cylinder head.
2
Inlet Valve Guide
B13321
Slide the auxiliary fitting (Item 1) [C] over the narrow end
of the pressfit tool until it makes contact with the middle
section of the tool. C
Slide the valve guide (Item 2) [C] over the narrow end of
the pressfit tool until it makes contact with the auxiliary 1 3
fitting.
Position the margin adjustment jig (Item 3) [C] above the
valve guide hole.
Press the valve guide into the valve guide hole until the 2
auxiliary fitting meets the margin adjustment jig.
The amount of valve guide protrusion will be thickness of
the margin adjustment jig which is 0.394 inch (10,0 mm).
B13320
742B, 743B Loader

A
Assembly
Install the valves.
Put oil in the valve seal and install the seal on the valve.
Install the valve spring and retainer.
Install the spring collet and the valve cap.
Install the thermostat.
NOTE: If a new cylinder head is installed be sure to
install the screw plugs which are shipped
with the new cylinder head.
B03624
Installation
Install a new gasket and Oring. Install a shim if there was
one removed. B
Install the cylinder head on the engine block.
Put oil on the bolts and nuts and tighten to the following
torque:
Flange Head Bolt . . . . . . . . . 6568 ft.lbs. (8892 Nm)
Bolt W/Washer 5861 ft.lbs. . . . . . . . . . . . (7983 Nm)
Use the tightening sequence as shown [A].
Lower the piston which is to be measured for the
clearance, between the cylinder head and the piston.
Put a piece of solder in the injector port.
B04068
Make sure the solder does not touch the valves [B].
0.00570.0073 in.
Turn the engine manually. C (0,1450,185 mm)
Remove the solder and measure it. The thickness must
be 0.0280.035 inch (0,70,9 mm).
If the measurement is not in the specifications, remove
the cylinder head and add the correct shim between the
cylinder head the engine block.
Install the cylinder head and tighten the bolts and nut [A].
NOTE: Be sure to torque the bolts and nuts again
after the engine has been operated for 30
minutes.
Install the push rods.
A02730
Install the water return pipe.
Install the rocker arms.
Tighten the rocker arm holding nuts to 15 ft.lbs. (20 Nm)
torque.
Install the alternator, belt and shield.
Install the intake manifold.
Install the injector nozzle with a new copper gasket.
Tighten to 2236 ft.lbs. (3049 mm) torque.
Install the injector tubelines.
Adjust the valve clearance. Make sure the piston is at
T.D.C. when making the adjustment [C].
Install the valve cover.
742B, 743B Loader
7A19 Service Manual
ENGINE REPAIR Detach Governor Spring
Remove the cylinder head. (See Page 7A14.)
A on the Side
of Fork Lever (2)
Remove the push rods.
Remove the starter. (See ELECTRICAL SYSTEM
Section 6.)
Gearcase
Remove the injector pump. (See Page 7A3.)
Gearcase Removal
Remove the governor spring from the governor fork [A]
& [B].
Fork Lever B11493
B03676
Remove the plate (Item 1) [C] for speed control and the
governor spring (Item 2) [C]. C
1
B03647
Remove the valve tappets [D]. D
B13367
742B, 743B Loader

ENGINE REPAIR (Contd)
Gearcase Removal (Contd)
A
Remove the start spring from the gearcase [A] & [B].
Gearcase
Detach Start
Spring on the
Side of the
Fork Lever (2) Gearcase B11493
Straighten the washer on the crankshaft sheave. Remove

the nut and washer. B
Installation: Tighten the nut to 101110 ft.lbs.
(137149 Nm) torque.
After installation, bend the washer on the sheave.
B03678
The tool listed will be needed for the following procedure:

MEL1234 Crankshaft Nut Socket C
Use a puller and remove the engine crankshaft sheave
[C].
Remove the key.
Remove the bolts from the gearcase.
B03694
Remove the gearcase [D].

D
B04095
742B, 743B Loader

7A21 Service Manual
A
Timing Gear, Camshaft And Oil Pump Removal
Remove the crankshaft collar (Item 1) [A], Oring, oil
slinger and the gear collar.
Remove the snap ring on the idler gear.
B03637
Remove the idler gear (Item 1) [B].

Remove the idler gear collar (Item 2) [B] from the shaft.
B
1
Straighten the washer on the bolt for the camshaft stop.
Remove the bolt for the camshaft stop.
B03699
Remove the camshaft [C].

Remove the three bolts that hold the fork lever on the fuel
C
camshaft.
Remove the stop for the fuel camshaft.
B03655
Remove the fuel camshaft and the fork lever at the same
time [D]. D
B03649
742B, 743B Loader

7A22 Service Manual
Timing Gear, Camshaft And Oil Pump Removal
A
(Contd)
Remove the crankshaft gear with a puller [A].
Remove the key.
Straighten the washer on the gear of the oil pump.
Remove the bolt on the gear of the oil pump.
B03686
Remove the gear pump (Item 1) [B].

Remove the oil pump bolt.
B
Remove the oil pump (Item 2) [B]. 1
B03658
Pistons And Crankshaft Removal

Remove the oil pan. C
Remove the screen [C].
NOTE: Do not damage the Oring.
Straighten the washer on the connecting rod bolts.

Remove the connecting rod bolts.
B04124 B03688
NOTE: Two types of bolts are used [D]. Install in

matched pairs only. Do not mix on same rod. D
Remove the cap and the bearing from the connecting rod
[C].
Tightening Torque
Installation: Tighten the rod cap bolts to torque as 3336 ft.lbs. (4549 Nm)
follows:
12
Machine Bolt (13 mm size head0 mm
2731 ft.lbs. (3742 Nm)
Cold Forged Flange Bolt
Forged Bolt (12 mm size head)
3336 ft.lbs. (4549 Nm)
742B, 743B Loader

7A23 Service Manual
Piston And Crankshaft Removal (Contd)
A
Remove the piston from the engine block [A].
NOTE: Be sure the pistons are marked so they will be
returned to the same cylinder.
Straighten the washer on the flywheel bolts.

Remove the bolts from the flywheel.
Use a puller to remove the flywheel.
Straighten the washer on the bolts that hold the main B03625
bearing in position.
Remove the main bearing bolts from the engine block [B]. B
Installation: Tighten the main bearing bolts to 4751
B03644
Straighten the washer on the bolts that hold the main

bearings in position. C
Remove the bolts.
Install two bolts in the rear cover and pull the cover out
[C].
B03648
Remove the crankshaft from the rear of the engine [D].

NOTE: Do not damage the crankshaft when
D
removing it from the engine block.
Straighten the washer on the bolts of the main bearings.
B04126
742B, 743B Loader

7A24 Service Manual
742B(S/N509418001&Above),743B(S/N509318001&Above)ServiceManual#6720772EngineServiceSectionPart1of5
Piston And Crankshaft Removal (Contd)

A
Remove the bolts from the bearing cap halves [A].
Remove the halves of the main bearings.
NOTE: When installing the bearing cap halves, make
sure to position the markings on the bearing
caps toward the flywheel. Thrust washers
must be installed with oil grooves facing
outward.
B04092
Timing Gear And Camshaft Service

B
Measure the camshaft bearing in the engine block [B].
The specification is 1.57481.5758 inch (4040,03 mm).
The wear limit is 0.0020.0036 (0,050,09 mm).
B03620
Measure the camshaft journal [C].

C
The specification is 1.57221.5728 inches
(39,93439,950 mm). The wear limit is 0.0020.0036
inch (0,050,09 mm).
If the measurements are not within the specifications
replace the needed parts.
Put the camshaft on Vblocks.
Put a dial indicator on the journals.
Turn the camshaft at a slow rate.
A02761
The wear limit is 0.0008 inch (0,02 mm) [D].

D
If the camshaft measurements are not within the
specification replace the needed parts.
A02760
742B, 743B Loader

7A25 Service Manual
Timing Gear And Camshaft Service (Contd)
A
Make a measurement of the highest point on each
camshaft lobe [A].
The specifications are 1.3134 inches (33,36 mm).
The wear limit is 1.3115 inches (33,31 mm).
B05001
NOTE: After the crankshaft is installed, check the

clearance for the camshaft gear.
B
Install a dial gauge.
Hold one gear while turning the other gear [B].
The specification is 0.0060.0045 inches (0,150,11
mm). The wear limit is 0.0118 inch (0,3 mm).
B03672
Servicing The Connecting Rods And Pistons

Remove the piston rings (Item 1) [C]. C
Remove the piston pin (Item 2) [C].
2
1
B03621
NOTE: Make sure to mark the piston and the

connecting rod so they will be assembled
correctly [D].
D
1. Align the marks
with each other.
2. Face the marks

toward the injection
pump.
A02903
742B, 743B Loader

7A26 Service Manual
A
Servicing The Connecting Rods And Pistons
(Contd)
Measure the piston pin hole [A].
The specifications are 0.90550.9060 inch (2323,013
A02733
Measure the piston pin (Item 1) [B] and the connecting

rod busing (Item 2) [B]. B
The clearance specification is 0.00060.0026 inch
(0,00150,07 mm).
The allowable limit is 0.0059 inch (0,149 mm) If the
clearance exceeds the allowable limit, replace the part.
NOTE: When the replacement bushing is installed,
be sure to drill the oil hole in the bushing.
Deburr the hole after drilling [B].
2
1
B03633
Put the piston ring on the bottom of the cylinder.

C
Check the clearance of the ring gap [C].
The specification is 0.00180.0177 inch (0,0460,45
Install the connecting rod on the tool for checking
connecting rod alignment.
B03622
Check the clearance at the piston pin area [D].

D
The specifications are 0.0008 inch ( 0,02 mm).
The wear limit is 0.0020 inch (0,05 mm).
NOTE: Be sure the bushing diameter of the

connecting rod is within specification.
B04067
742B, 743B Loader

7A27 Service Manual
A
Crankshaft Service
NOTE: If a new crankshaft is used, be sure the plugs
that come with the crankshaft are installed in
the crankshaft or engine damage will occur.
Put the crankshaft on Vblocks.

Put a dial indicator on the center journal and turn the
crankshaft slowly [A].
The specifications are 0.0008 inch (0,02 mm).
The wear limit is 0.0031 inch (0,08 mm). A02763
Check the inside diameter of the crankshaft bearing in the

engine block [B]. B
The specification is 2.04652.0488 inches
(51,9852,039 mm). The wear limit is 0.0079 inch (0,2
mm).
B03631
Check the outside diameter of the #1 crankshaft journal

[C]. C
The specification is 2.04412.0449 inches (51,9251,94
B03618
Check the connecting rod bearings [D].

The specifications are 1.73271.7343 inches
D
mm).
120
A02727
742B, 743B Loader

7A28 Service Manual
Crankshaft Service (Contd)
A
Check the connecting rod journals [A].
The specifications are 1.73071.7313 inches
mm).
A02716
If the connecting rod journals are not within specifications

A
grind the journals as follows [B]. B
a. Crankshaft corner radius must be 0.127R inch B
.0079 inch (3,5R 0,2 mm).
b. The oil hole must be chamfered to 0.03940.0591R
inch (1,01,5R mm).
A
A02716
Install the crankshaft and check the end play [C].

Normal end play is 0.00590.0122 inch (0,150,31 mm). C
Replace the thrust bearings on the main bearing if end
play exceeds 0.020 inch (0,5 mm).
B09565
Cylinder Liner Service

D
Check the inside diameter of the cylinder liner [D].
The tools listed will be used for the following procedure:
MEL1060 Ridge Reamer
MEL1180 Dry Liner Puller
B04066
742B, 743B Loader

7A29 Service Manual
Cylinder Liner Service (Contd)
A
To find the maximum wear check the inside diameter in
three different locations [A].
The specifications are 3.22833.2292 inches (8282,021
mm). The wear limit is + 0.0059 inch (+ 0,15 mm).
When the cylinder liner has more wear than
specifications, bore and hone the cylinder to
3.24803.2489 inches (82,49982,522 mm).
NOTE: Make sure you use the correct oversize
pistons and rings.
A02727
If the cylinder liner is not within the specifications, replace

I J
the cylinder liner. These are dry liners. B
Remove the cylinder liners. K
Clean and rub oil in the bores of the engine block. L
Clean and put oil on the outside of the cylinder liners.

Install the cylinder liners into the engine block with the
inside and outside diameter chamfered end down. M
H G
The top of the liner must be even with the top of the engine N
block machined surface.
After installation bore and hone the cylinder liner to
3.22833.2291 inches (8282,019 mm).
Lubrication System F
The lubrication system consists of a trochoid rotortype
driven oil pump, oil filter cartridge, oil pressure regulating
valve, oil switch, and oil filter [B].
B
C E
Oil is siphoned by the oil pump (b) from the oil pan (o)
through the oil filter (a), where the oil is kept at 4164 PSI D
(290441 kPa) by an oil pressure regulating valve (c)
installed in the gearcase. The oil flows towards the filter O
cartridge where it will be further filtered. To insure the
supply of lubricating oil, a bypass valve (d) is provided, (a) Pump Screen A
the valve opens when the filter element (e) is restricted (b) Oil Pump
from the filter cartridge, the pressurized oil is then (c) Pressure Regulating Valve
distributed into two area; some will be fed through (d) ByPass Valve
crankshaft passages to the crank pin bearing and the rest (e) Filter Element
to the rocker arm shaft (i) through the frame. Oil then (i) Rocker Arm Shaft
(f) Crankshaft (j) Rocker Arm
returns to the oil pan by gravity. (g) Piston (k) Push Rod
(h) Idle Gear (l) Tappet
The oil pressure switch (m) will indicate when oil pressure
drops below 7 PSI (48 kPa). The oil pressure switch is (m) Oil Pressure Switch
connected to the oil pressure gauge in the dash panel. If (n) Camshaft
the pressure reads low or zero while the engine is in (o) Oil Pan B09194
normal operation, stop the engine immediately and check
the oil level.
742B, 743B Loader

7A30 Service Manual
Oil Pump Service
A
Check the clearance between the inner and outer rotor
[A]
The clearance for the inner rotor is 0.00390.0063 inches
mm).
B03616
Check the clearance between the outer rotor and the

body of the oil pump [B]. B
The clearance for the outer rotor is 0.00430.0075 inches
(0,110,19 mm).
At full rated engine speed, the normal oil pressure is
4256 PSI (290386 kPa) and a minimum of 35 PSI (241
kPa).
A02732
Water Pump Service

Remove the water pump from the gearcase [C]. C
B05318
Put the water pump is a vise and remove the nut [D].
Remove the pulley using a puller. D
Remove the key.
Remove the snap ring.
B05324
742B, 743B Loader

7A31 Service Manual
Water Pump Service (Contd)
A
Drive the shaft out of the impeller side [A].
B05325
Install the new seal [B].

Install the shaft
B
Put the water pump in a vise and tighten the nut to 5057
Install the water pump assembly on the gearcase with a
new gasket.
A02783
742B, 743B Loader

7A32 Service Manual
ENGINE ASSEMBLY
Crankshaft Installation
A
Install the main bearing case on the crankshaft journals
with marks toward the flywheel end.
Tighten the bolts to 2125 ft.lbs. (2834 Nm) torque. Main
Bearing
Install the thrust bearing with the oil grooves to the Case
outside.
Install the crankshaft in the engine block.
Each main bearing is numbered for correct location. Case
Bolt
Make sure the oil holes in the main bearings are in A02736
alignment with the holes in the engine block [A].
Install the main bearing case bolts and tighten to 4750
B
Install new seals int he crankshaft rear cover.
Install the rear cover and tighten the bolts to 1315 ft.lbs.
(1820 Nm) torque.
Installing The Pistons.

The tools listed will be needed for the following procedure:
MEL1063 Ring Compressor Alignment
MEL1064 Piston Ring Expander Marks
B03614
Assemble the connecting rod to the piston.
NOTE: Make sure the marks on the piston and the
connecting rod are in the same direction. C
Install the rings on the piston [B].
Position the top ring so the gap is not lines up with the
piston pin. Position the other rings so there is a gap every
90.
Use a ring compressor to install the pistons in the engine
block with the marks away from the camshaft.
Align the bearing cap on the connecting rod [C].

Put oil on the bolts, install them in the bearing caps and A02731
tighten to 2630 ft.lbs. (3541 Nm) torque.
Install the oil pump tube and screen.
D
Install a new oil pan gasket and install the oil pan.
Installing The Camshaft And Timing Gears

Install the oil pump and tighten the bolts to 6072 in.lbs.
(6,78,1 Nm) torque [D].
Install the gear and tighten the nut.
Install the key and the gear on the crankshaft.
B03658
742B, 743B Loader

7A33 Service Manual
ENGINE ASSEMBLY (Contd)
Instaling The Camshaft And Timing Gears (Contd)
A
Install the fuel camshaft and the fork lever at the same
time [A].
Install the stop bolt on the fork lever. Tighten the bolt to
6072 in.lbs. (6,88,1 Nm) torque.
Install the bolts and tighten to 1315 ft.lbs. (1820 Nm)
torque.
B03649
Install the camshaft and tighten the bolts to 1315 ft.lbs.

(1820 Nm) torque [B].
B
B03655
Install the idle gear [C].

C
B03699
Make sure the timing marks are in correct alignment [D].

D Gear Marks
Install the snap ring on the idler gear shaft.
Cam Gear
Injection Pump
Gear Idle Gear
Oil Pump Crank Gear

Drive Gear
A02771
742B, 743B Loader

7A34 Service Manual
Installing The Camshaft And Timing Gears (Contd)
A
Install the oil slinger (Item 1) [A]. Put oil on the Oring and
install the Oring (Item 2) [A] and the collar (Item 3) [A].
1 3
B04098
Gearcase Installation
Install the Oring and the oil seal in the gearcase cover
B
[B].
NOTE: Put oil on the oil seal.
Install the gearcase cover and bolts. Tighten the bolts to

Install the crankshaft sheave and tighten the nut to
101116 ft.lbs. (137157 Nm) torque.
Orings
Oil Seal
B03617
Install the start spring [C].

C
B03678
Install the speed control plate and governor spring [D].

D
NOTE: Do not drop the governor spring into the
gearcase.
B03647
742B, 743B Loader

7A35 Service Manual
A
Gearcase Installation (Contd)
Connect the governor spring [A].
Install the injector pump. (See Page 7A3.)
Install the cylinder head. (See Page 7A19.)
Install the engine. (See Page 7A9.)
B03676
742B, 743B Loader

7A36 Service Manual
(Mitsubishi 742B)
Page
Number
CAMSHAFT
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B29
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B29
CARBURETOR
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B11
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B7
Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B11
Governor Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B12
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B11
CRANKSHAFT AND MAIN BEARINGS
Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B43
Checking Oil Clearance (Plastic Gauge) . . . . . . . . . . . . . . . . . . . . . . . . 7B44
Crankshaft End Play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B45
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B43
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B44
Rear Oil Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B45
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B43
CYLINDER HEAD
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B31
CYLINDER LINERS
Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B42
DISTRIBUTOR
Checking Centrifugal Advance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B6
Checking Vacuum Advance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B6
Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B6
Point Gap Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B5
ENGINE
ENGINE BELT SHIELD
ENGINE COMPRESSION
Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B3 MITSUBISHI
ENGINE FLYWHEEL & UJOINT (742B)
Flywheel Ring Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B24
ENGINE MUFFLER
FRONT CASE AND OIL PAN
FRONT CASE SEAL
FUEL PUMP
Checking The Fuel Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B13
Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B13
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B13
742B, 743B Loader

7B1 Service Manual
(Mitsubishi 742B (Contd)
Page
Number
IGNITION TIMING
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B4
OIL COOLER AND BLOWER HOUSING
OIL PUMP
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B52
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B52
Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B53
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B52
PISTON AND CONNECTING ROD
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B37
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B36
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B37
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B38
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B36
PISTON PIN
Assembly Of The Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B40
Installation Of The Piston Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B41
Removal Of The Piston Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B40
RADIATOR
ROCKER ARMS
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B26
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B26
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B25
THERMOSTAT
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B56
TIMING BELT
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B46
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B49
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B48
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B47
TROUBLESHOOTING
Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B1
VALVES
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B32
Reconditioning The Valve & Valve Seat . . . . . . . . . . . . . . . . . . . . . . . . 7B33
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B32
Valve Guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B34
Valve Seat Inserts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B33
Valve Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B34
VALVE CLEARANCE
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B2
WATER PUMP
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B55
742B, 743B Loader

7B0 Service Manual
TROUBLESHOOTING
Chart
The following troubleshooting chart is provided for assistance in locating and correcting problems which are most common.
Many of the recommended procedures must be done by authorized Bobcat Service Personnel only.
PROBLEM CAUSE
Slow cranking speed. 1, 2, 3, 4
Engine will not start. 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12
Rough idle. 9, 13, 14, 15, 16
Abnormal combustion. 9, 11, 14, 17, 18, 19, 20, 21
Engine noise. 8, 14, 22, 23, 24, 25, 26, 27, 28, 29
Acceleration insufficient. 5, 9, 11, 31, 32
Power insufficient. 5, 8, 9, 11, 12, 13, 14, 15, 17, 18, 21, 26, 31, 33, 34
Too much fuel consumption. 8, 9, 11, 12, 13, 14, 15, 16, 18, 26, 32
Too much engine oil.
consumption. 26, 35, 36, 37, 38, 39, 40, 41, 42, 43, 44, 45
Excessive engine vibration. 9, 11, 17, 31, 34, 45, 46
Overheating. 9, 11, 13, 20, 30, 47, 48, 49, 50
High Oil Pressure. 4, 51, 52

1. Battery capacity low. 27. Excessive camshaft end play.
2. Bad electrical connections. 28. Crankshaft thrust bearing worn.
3. Faulty starter motor. 29. Timing belt worn.
4. Incorrect grade of oil. 30. Water pump or fan belt faulty.
5. Burnt valve. 31. Poor compression.
6. Intake manifold gasket leaking. 32. Carburetor accelerator pump faulty.
7. Carburetor mounting loose. 33. Overheating.
8. Piston, rings & cylinder worn. 34. Cold running.
9. Cylinder head gasket leaking. 35. Oil pan drain plug is loose.
10. Faulty electrical wiring. 36. Oil pan bolts are loose.
11. Faulty ignition system. 37. Oil pan gasket is faulty.
12. Fuel system problem. 38. Timing gear cover is loose or gasket
13. Restriction in the air cleaner. is broken.
14. Valve clearance not correct. 39. Crankshaft front seal leaking.
15. Worn valves and seats. 40. Crankshaft rear seal leaking.
16. Worn valve stems or guides. 41. Valve cover gasket is leaking.
17. Vale stuck. 42. Fuel pump loose or faulty gasket.
18. Weak valve springs. 43. Oil filter mounting loose.
19. Carbon accumulated in combustion 44. Plugged oil return hole.
chamber. 45. Piston rings stuck.
20. Restriction in the water jacket 46. Faulty engine mounting.
21. Carburetor mixture too lean. 47. Exhaust pipe restriction.
22. Worn or damaged bearings. 48. Faulty thermostat.
23. Connecting rod bent. 49. Plugged radiator.
24. Piston or piston pin worn. 50. Coolant level low.
25. Burnt piston. 51. Switch is defective.
26. Piston rings damaged. 52. Pressure relief sticking closed.
742B, 743B Loader

7B1 Service Manual
VALVE CLEARANCE
Adjustment
A Intake
0.0006
Exhaust (0,15 mm)
0.010 Hot
NOTE: Always set the valve clearance after the (0,25 mm)
cylinder head bolts are tightened to the Hot
correct torque.
Warm the engine until it is at operating temperature.

Valve clearance [A].
Intake Valve . . . . . . . . . . . . . . 0.006 inch (0,15 mm) Hot
Exhaust Valve . . . . . . . . . . . . 0.010 inch (0,25 mm) Hot
B09720
Stop the engine. Remove the valve cover.
Position the piston at T.D.C.
B
Loosen the lock nut.
Adjust the valve clearance by turning the adjusting bolt
and measuring with a feeler gauge [B].
Tighten the lock nut.
Repeat the procedure for each set of valves.
Start the engine, run at idle speed and check the
clearance again. Make adjustment as needed.
B09716
742B, 743B Loader

7B2 Service Manual
ENGINE COMPRESSION
Checking
A
procedure:
OEM1073 Compression Gauge & Hose
The engine must be at operating temperature.
Remove the spark plugs [A].
Installation: Tighten the spark plugs to 1822 ft.lbs.
(2430 Nm) torque.
B09883
Connect a compression gauge [B].

The engine should be turning at about 250 RPM.
B
The compression should be about 150 PSI (1024 kPa)
with no more than 10% difference between cylinders.
B09882
742B, 743B Loader

7B3 Service Manual
IGNITION TIMING
A
Procedure
Mark the crankshaft pulley notch and 5 BTDS mark with
chalk [A].
Connect the timing light to the No. 1 spark plug wire.
Connect the negative and positive cables of the timing
light to the correct battery terminals.
B09941
When the engine is running during service, the

steering levers must be in neutral and the B
parking brake engaged. Failure to do so can
cause injury or death.
W20060284
Disconnect the vacuum line.

Start the engine. Run the engine speed at 600650 RPM.
Check the timing setting [B].
B09943
If the timing is not correct, loosen the distributor mounting

nut [C]. C
Turn the distributor until the timing is at at 5 BTDC.
At 2800 RPM and vacuum line off, the timing should
advance 10.
B09942
742B, 743B Loader

7B4 Service Manual
DISTRIBUTOR
A
Turn the crankshaft until No. 1 piston is at T.D.C. on
compression stroke.
Disconnect the negative battery cable.
Remove the distributor cap [A].
Disconnect the vacuum hose.
B09701
Remove the distributor mounting nut [B].

B
B09700
Installation: Align the mating mark (Item 1) [C] on the

distributor housing with the mark on the distributor gear.
C
1
Point Gap Adjustment

Remove the distributor cap.
Remove the rotor. B09678
Turn the crankshaft until the points are wide open. Check
the breaker point gap with a feeler gauge, if it is out of Contact Arm
specifications, adjust as follows: D
Breaker Point Gap . . . . . . . . . . . . . . . . 0.0180.021 inch Breaker
(0,480,53 mm) Point
Gap
Loosen the two lock screws.
Put a screwdriver blade into the hole (Item 1) [D].
Adjust the points to the correct specifications. 1
Tighten the two lock screws.
Lock Screw
NOTE: After the breaker points are adjusted, you
must time the engine. (See Page 7B4.) B09784
742B, 743B Loader

7B5 Service Manual
DISTRIBUTOR (Contd)
A 3 4
5
Disassembly And Assembly 1
2
Use the following procedure to disassemble and
assemble the distributor [A]: 7
6
Remove the rotor (Item 3) [A]. Remove the snap ring from
the spindle of the breaker base (Item 7) [A]. 12
11
Remove the screws holding the vacuum advance (Item 10
21) [A] and removal. Disconnect the wires and remove 8 9
the terminal. 10
13
Remove the breaker points. Remove the cam assembly.
Remove the springs (Item 10) [A] and weights (Item 9)
[A].
Remove the roll pin (Item 19) [A] from the gear (Item 20) 21
[A]. Remove the gear and shaft assembly. 22
Checking Centrifugal Advance

Run the engine at the idle low RPM. Remove the vacuum 18
hose. Slowly increase the engine RPM to check advance. 20
17
1. Excessive Advance 16
Weak Springs or broken.
2. Insufficient Advance
Faulty operation of the centrifugal weights or cam. 19
14
Checking Vacuum Advance
15
Set engine speed at 2800 RPM. Check advance by
disconnecting and connecting the vacuum hose. Timing
should advance 10. For an accurate check, connect a 1. Cap 12. Washer
vacuum pump and run engine at idle RPM. Slowly apply 2. Carbon Contact 13. Oil Seal
vacuum to check advance. 3. Rotor 14. Terminal
4. Wire 15. Packing
1. Excessive Advance 5. Arm Support 16. Housing
Weak vacuum control spring or broken. 6. Wire 17. Oring
7. Breaker Base 18. Washer
2. Insufficient Advance 8. Cam 19. Roll Pin
Breaker plate binding or diaphragm broken. 9. Weight 20. Gear
10. Spring 21. Vacuum Control
11. Shaft 22. Condenser
B09824
742B, 743B Loader

7B6 Service Manual
CARBURETOR
A Pilot Air Jet No. 1 Pilot Air Jet No. 2

Pilot Jet
Fuel
Ignition Switch
Fuel
Air
Bypass
Solenoid Primary Main Jet
Bypass Screw
Pilot Throttle
Mixture Adjusting Outlet Valve
Screw
B09714
Description
The lowspeed system provides airfuel mixture for
smooth lowspeed engine operation for lightload
performance [A].
Fuel from the float chamber is sent through the main jet
and fuel passage to the pilot jet where the fuel is metered.
At the same time, air is fed through the venturi air orifice
and pilot air jet No. 2 to the pilot air jet No. 1 where the air
is metered then, air is mixed with the fuel.
The flow of airfuel mixture is adjusted by the bypass
screw and enters the air horn through the bypass hole
and pilot outlet. It mixes with a small amount of air that
goes past the closed or slightly open throttle valve. The
final mixture flows into the cylinders.
The mixture adjusting screw is provided for adjusting
airfuel mixture necessary for idle.
The bypass screw is for adjusting the flow of fuel to the
bypass hole which provides mixture for engine operation
from off idle to a medium load operation.
The fuel shutoff solenoid, in the lowspeed system,
functions as follows: When the key switch is ON it opens
the valve to open the fuel line. When the key switch is OFF
it closes the fuel feed line and prevents spontaneous
running of the engine.
742B, 743B Loader

7B7 Service Manual
CARBURETOR (Contd)
Description (Contd)
A
Bimetal
Element
The idle compensator is operated by a bimetal element Valve
[A].
When the carburetor ambient temperature rises during
idle operation, the bimetal bends enough to open the
compensator valve. Now additional air, from the air horn,
can flow through the air passage directly to the intake
manifold. This leans out the mixture to make up for added
gasoline vapor coming from the float chamber.
Air Passage
B09713
The main metering system functions as follows [B]:

Primary
The wider the throttle valve opens, the faster the air flow
B Inner Venturi
Main Venturi
is in the venturi. As the vacuum becomes greater, the
main nozzle will inject fuel.
The main metering system is provided with the bleed Main Air Jet
valve pressfitting into the inner venturi and the main air
jet.
Fuel metered by the main jet is bled by air from the main Main Well
air jet and enters the bleed pipe through the holes. The
main nozzle flows the fuel into the engine.
If percolation of the fuel is present along the main well,
vapor can escape from the main air jet through outside
bleed pipe, thus preventing fuel from spurting from the Main Jet B09712
main nozzle.
742B, 743B Loader

7B8 Service Manual
CARBURETOR (Contd)
A Valve
Description (Contd)
The enrichment system does the following functions [A]:
This system provides additional fuel to the main metering
system during highspeed large torque operation. The
diaphragm is actuated by intake manifold vacuum and
spring to open or close the fuel feed line. Vacuum
Chamber
During partial throttle operation, the manifold vacuum is Spring
applied to the vacuum chamber and acts on the
diaphragm to close the valve against spring force. Enrichment Jet
When the throttle is opened, manifold vacuum
decreases. This allows the diaphragm spring to open the B09711
valve. Now, more fuel from the float chamber can flow
through the valve into the enrichment jet.
B Pump Jet
The acceleratorpump system does the following Valve
functions [B]: Weight
Rapid opening of the throttle, requires a sudden demand Check
for additional fuel. Valve
Fuel from the inlet check valve is sent tot he pump nozzle
through the outlet check valve by movement of the
diaphragm. The diaphragm is pushed by the pump lever
linked to the throttle valve.
Pump
When the engine is decelerated, the diaphragm is pushed Lever
back by the spring and the chamber is refilled with fuel. Membrane
Inlet Check Valve B09726
742B, 743B Loader

7B9 Service Manual
CARBURETOR (Contd)
A
Disconnect the air cleaner hose at the carburetor air horn.
Disconnect the wire at the shutoff fuel solenoid [A].
B09872
Disconnect the choke cable.

Disconnect the fuel line [B].
B
Disconnect the vacuum hose.
B09933
Disconnect the throttle linkage (Item 1) [C].

C
B09873
Remove the four mounting nuts [D].

D
Lift the carburetor from the intake manifold.
B09874
742B, 743B Loader

7B10 Service Manual
CARBURETOR (Contd)
Disassembly And Assembly
A
Disassemble and assemble the carburetor as shown [A].
Use the correct tools to prevent burrs or scratches.
2
Keep the parts neatly and in order to prevent wrong
assembly.
Do not remove the inner venturi unless it is necessary.
3
Do not remove the bypass screw unless it is necessary. 4 11
1 12
Do not disassemble the throttle shaft or remove the plug
in the throttle plate. 7 6 14
Inspection 5
15
Clean the parts thoroughly with carburetor solvent.
13
Use air pressure to blow fuel passages and other parts
dry. 8 16
Check the needle valves for correct contact, replace as 9
needed. 19
Check the screen diaphragm and pilot screw seats for 18
damage. 17
Check the throttle valve for wear and damage and be sure 10 20
the plug in the throttle plate is tight.
Check the linkage for correct function.
Check the acceleration pump for correct function as
follows: 1. Float
2. Float Chamber Cover
Fill the pump chamber with fuel, operate the throttle lever 3. Screen
and check for fuel spraying condition from the accelerator 4. Needle
nozzle. 5. Main Body
6. Main Jet
7. Enrichment Body Assembly
Push the connecting rod of the depression chamber, plug 8. Diaphragm
the vacuum passage with a finger, release the connecting 9. Pump Cover
rod and check for leakage from the diaphragm. 10. Throttle Body
11. Choke Connecting Rod
Check the float for being deformed, leakage, damage to 12. Inner Venturi
the lip, wear of the float lever pin hole and the float lever 13. Pilot Jet
14. Choke Operating Lever
bracket. 15. Speed Adjustment Screw
16. Bypass Screw
Adjustment 17. throttle Stop Lever
18. Abutment Plate
If the float level is out of alignment with the level mark, 19. Throttle Lever
adjust the float by adding or removing the number of 20. Mixture Adjustment Screw D01771
packings at the needle valve seat [A].
a slight difference of the float level from the level mark
does not effect the carburetor or engine performance, it
B
Packing
is normal if the float is in the circle of the level mark.
Level Mark
When the engine is running during service, the

steering levers must be in neutral and the
Sight Glass
parking brake engaged. Failure to do so can
cause injury or death.
W20060284 Float B09727
742B, 743B Loader

7B11 Service Manual
CARBURETOR (Contd)
A
Adjustment (Contd)
Set the engine idle speed (Item 1) [A] to 850950 RPM
at operating temperature.
Turn the idle fuel adjustment (Item 2) [A] in until the
engine RPM decreases. Make a note of this position.
Turn the idle fuel adjustment (Item 2) [A] out until the
engine RPM decreases. Adjust the idle fuel adjustment
between the two positions.
1
2
B09870

B
area, fresh air must be added to avoid 2 3
gases which can kill without warning.
W20501285
Governor Adjustment
4
NOTE: Adjust engine timing. (See Page 7B4.) 1
Loosen three governor mounting bolts.
Adjust governor belt tension to 1/4 inch N07058
movement at middle of belt. Keep governor
level and tighten the bolts.
Disconnect throttle rod (Item 1) [B].

C
Hold carburetor linkage (Item 3) [B] and governor linkage
(Item 4) [B] against their stops and tighten the screws
(Item 2) [B].
Check the governor throttle lever for maximum travel.
Start the engine.
1 2
Check that the engine idle speed is at 700750 RPM while
holding governor lever against the idle stop.
Set the throttle lever fast position stop bolt (Item 1) [C] at
rear of slot. N07076
Push throttle lever fully forward.

Set engine RPM at 29002975 RPM by adjusting the ball
joint (Item 3) [B] and high speed stop on the governor.
Pull throttle lever back until carburetor lever is against the
idle stop screw.
Set and tighten the slow position stop bolt (Item 2) [C]
against the throttle lever.
742B, 743B Loader

Revised July 96 7B12 Service Manual
FUEL PUMP
A
Disconnect the fuel lines from the fuel pump [A].
B09704
Remove the three bolts from the fuel pump [B].

Installation: Put Threebond 4A Sealant between the
B
cylinder head and gasket.
B09680
Remove the fuel pump from the cylinder head [C].

C
Inspection
Check the rocker arm for smooth operation. Also check
the spring for being weak and the pin for wear.
Check the pump body and cover for cracks and damage.
Check The Fuel Pump

Disconnect the outlet hose from the fuel pump.
Connect a gauge to the port.
B09681
Start the engine and measure the delivery pressure. If not
within specifications, replace as needed.
Delivery . . . . . . . . . . . . . . . . 2.11 qts. (2 L) @ 5000 RPM D
Closed Delivery Pressure . . 3.75 PSI (25,534,5 kPa)
Fuel Filter
the fuel filter is located in front of the air cleaner [D].
Change the fuel filter every 500 hours of loader operation.
B09903
742B, 743B Loader

7B13 Service Manual
ENGINE BELT SHIELD
A
Remove the bolt from the belt shield above the alternator
[A].
B09836
Remove the bolt from the governor bracket [B].

Remove the bolt below the governor which fastens the
B
belt shield to the engine block.
B09966
Remove the bolt from the alternator mounting bracket

[C].
C
B09965
Remove the belt shield from the engine [D].

D
B09640
742B, 743B Loader

7B14 Service Manual
ENGINE
A
Remove the battery from the loader. (See ELECTRICAL
SYSTEM Section 6.)
Disconnect the wire from the charge pressure switch [A].
B09967
B
Disconnect the wire from the port block [B].
B09812
C
Disconnect the electrical connectors from the electrical
harness [C].
Remove the belt shield. (See page 7B14.)
B09808
D
Remove the radiator hose from the water pump [D].
B09901
742B, 743B Loader

7B15 Service Manual
ENGINE (Contd)
A
Drain the coolant into a container [A].
Installation: Make sure to premix the water (50%) and
ethylene glycol (50%) before adding it to the cooling
system.
B09960
Remove the radiator hose from the thermostat housing

[B]. B
B09834
Disconnect the air cleaner hose [C].

Turn the fuel shutoff to the OFF position on the fuel tank. C
B09835
Disconnect the fuel line from the fuel pump [D].

D
B09900
742B, 743B Loader

7B16 Service Manual
ENGINE (Contd)
A
Mark all the wires from the coil and resistor for correct
installation.
Disconnect all the wires from the resistor and coil [A].
Disconnect the ground cable from the engine block
behind the governor.
Disconnect the throttle rod from the governor.
B09899
Remove the clamp from the exhaust pipe [B].

Disconnect the exhaust pipe.
B
B09961
Disconnect the wires from the starter solenoid [C].

Mark the wires at the starter solenoid for correct
C
installation.
B09982
Remove the four bolts, washers and nuts from the engine
mounting plate [D].
D
B09962
742B, 743B Loader

7B17 Service Manual
ENGINE (Contd)
A
Hook one end of the chain hoist into the lift hook on the
water pump end of the engine [A].
B09838
Lift the engine a small amount and slide it toward the rear
of the loader until the engine mounting plate is just over
the rear edge of the loader frame [B].
B
B09980
Lower the chain hoist. Connect the other end of the chain
hoist to the lift hook on the flywheel end of the engine [C]. C
B09913
Lift the engine. Slide it out of the loader frame [D].

D
Installation: Move the engine into the loader until the
ujoint is in the blower housing. Have a second person
reach behind the blower housing (at the hydrostatic
pumps) and guide the ujoint on the splines of the
hydrostatic pump shaft.
B09981
742B, 743B Loader

7B18 Service Manual
OIL COOLER AND BLOWER HOUSING
A
Remove the engine from the loader. (See Page 7B15.)
Remove the bolts from the blower housing cover plate
[A].
B09955
Remove the cover plate [B]. B
B09954
Disconnect the tubeline from the filter housing [C]. C
B09953
Disconnect the tubeline from the oil cooler [D].

D
B09952
742B, 743B Loader

7B19 Service Manual
OIL COOLER AND BLOWER HOUSING (Contd)
A
Remove the tubeline from the blower housing [A].
B09951
Disconnect the other tubeline from the oil cooler [B].

B
B09950
Disconnect the tubeline beside the blower housing [C].

C
B09949
Remove the tubeline from the blower housing [D].

D
B09945
742B, 743B Loader

7B20 Service Manual
OIL COOLER AND BLOWER HOUSING (Contd)
A
Remove the bolt and nut from the bottom of the blower
housing [A].
B09948
Remove the blower housing from the loader [B].

B
B09944
Remove the nuts from both sides of the oil cooler [C].
C
B09947
Lower and remove the oil cooler from the loader [D].
D
B09946
742B, 743B Loader

7B21 Service Manual
RADIATOR
A
Remove the oil cooler and blower housing from the
loader. (See Page 7B19.)
Remove the engine muffler. (See Page 7B23.)
Disconnect the overflow hose from the radiator [A].
B09957
Remove both radiator hoses from the radiator [B].

B
B09956
Remove the three bolts along the back edge of the

radiator [C]. C
Remove the three bolts along the front edge of the
radiator.
B09958
Lift the radiator from the loader [D].

D
B09911
742B, 743B Loader

7B22 Service Manual
ENGINE MUFFLER
A
Remove the two bolts at the back edge of the muffler [A].
B09959
Remove the four bolts from the bottom of the muffler [B].
Remove the muffler exhaust pipe clamp.
B
NOTE: The spark chamber plug may have to be
removed so there is enough clearance for the
muffler to be removed.
B09979
Remove the muffler from the loader [C].

C
B09977
Remove the plate between the muffler and the radiator.

D
B09978
742B, 743B Loader

7B23 Service Manual
A
Remove the four bolts from the ujoint mounting flange
[A].
Installation: Put LOCTITE on the bolt and tighten to
Remove the ujoint.
B09935
Remove the bolts from the cooling fan [B].

B
Nm) torque.
Remove the cooling fan.
B09934
Remove the bolts from the flywheel [C].

Installation: Tighten the bolts to 5560 ft.lbs. (7581 C
Nm) torque.
Remove the flywheel.
Flywheel Ring Gear

the ring gear on the flywheel is an interference fit. Heat the
ring gear enough to expand it and hit the ring gear with a
hammer, evenly, to remove it.
Clean the outer surface of the flywheel to give the ring
gear a smooth fit.
B09898
Clean the new ring gear and heat it to a temperature of
450500 F. (232260 C.).
Fit the ring gear over the flywheel. Make sure the gear is
on its seat correctly.
742B, 743B Loader

7B24 Service Manual
ROCKER ARMS
Removal
A 3 2
1
Remove the valve cover.
Remove the front upper cover from the timing belt.
Turn the crankshaft until No. 1 cylinder is at T.D.C.
compression stroke.
Make alignment of the mark on the camshaft sprocket
(Item 1) [A] with the timing mark (Item 2) [A] at the upper
cover back plate.
Make a mark on the timing belt (Item 3) [A] in alignment
with the other marks. B09718
Remove the camshaft bolt.

B
Put a small piece of old timing belt (Item 1) [B] between
the sprocket and sprocket holder. Do this to prevent the
camshaft sprocket from lowering to such an extent that
the timing belt comes off.
1
DO NOT turn the crankshaft after the camshaft
sprocket is removed because engine timing B9717
will be changed.
I21220297
C
Remove the camshaft spacer [C].
Remove the back plate for the upper cover.
Remove the bolts from the bearing caps for the camshaft.
Remove the front seal fro the camshaft.
Remove the rocker arms, rocker shaft and bearing cap
assembly.
B09719
742B, 743B Loader

7B25 Service Manual
ROCKER ARMS (Contd)
A
Removal (Contd)
Mark the rocker arms for correct assembly.
Remove the bearing caps, wave washers, springs and
rocker arms as shown [A].
#
*
Spring (common to both
rocker shafts)
Free length 2.10 (53 mm)
# 45 ft.lbs. (56 Nm)

* 1415 ft.lbs. (1720 Nm)
B09771
Inspection
Check the rocker arm surface that contacts the cam lobe
B
and the adjusting bolt ends that contact the valve stem
[B].
If worn or damaged, replace the rocker arm.
Check the rocker arm shaft for damage. Replace the
parts as needed.
Installation
procedure:
B09724
MEL1299 Camshaft Seal Tool
Install the right and left shafts into the front bearing cap.
Temporarily install the bolts to hold the shafts.
C 1
Left Rocker
Shaft
Make sure the end slots (Item 1) [C] at the front of the Right
shaft are in the up position. Rocker
Shaft
Install the rocker arms, springs and bearing caps in the
order shown [A].
Camshaft
Make sure to install the wave washer in the right direction Front
[A]. Bearing
Cap
After the rear bearing cap is installed, temporarily install
the bolts to hold them in position.
B09724
742B, 743B Loader

7B26 Service Manual
ROCKER ARMS (Contd)
A
Installation (Contd)
Install the assembled rocker arm shaft assembly into the
cylinder head.
Key
Position the camshaft key, at the front end, as shown [A].
Install the bolts in the camshaft bearing caps. Tighten the
bolts to 1415 ft.lbs. (1920 Nm) torque. 41
B09723
Use the camshaft seal installation tool and install the

camshaft oil seal [B]. B
Put engine oil on the seal lips before installing the seal. Oil Seal
B09721
Use a hammer and install the seal [C].

Install the back plate for the upper cover.
C Oil Seal
Camshaft Oil
Seal Installer
B09785
Put oil on the outer surface of the camshaft spacer and

install the spacer [D]. D
B09719
742B, 743B Loader

7B27 Service Manual
ROCKER ARM (Contd)
A
Pull the camshaft sprocket up, and install it on the
camshaft [A].
B09717
When the dowel pin hole on the camshaft sprocket does

not align with the dowel pin at the end of the spacer, the
camshaft can be turned by hitting the projections at the
B Pistons
No. 2 camshaft journal [B].
NOTE: Make sure the crankshaft is not turned for
correct alignment of the dowel pin and dowel
pin hole.
Install the bolt at the camshaft sprocket and tighten to

NOTE: Check to make sure the timing marks are still No 2 Cylinder
in alignment. Exhaust Cam
No 2 No 2 Cylinder
Install the upper front cover. Adjust the valve clearance. Journal Intake Cam B09722
Clearance (Cold)
Intake . . . . . . . . . . . . . . . . . . . . . . . 0.03 inch (0,08 mm)
Exhaust . . . . . . . . . . . . . . . . . . . . . . 0.07 inch (0,18 mm) C
Temporarily install the valve cover. Start the engine, run
until at operating temperature.
Set the valve clearance. (See Page 7B2.)
Before installing the valve cover, put Sealant on the half

plug at the cylinder head [C].
Install the valve cover and tighten the bolts to 4860
in.lbs. (5,46,8 Nm) torque.
B09693
742B, 743B Loader

7B28 Service Manual
CAMSHAFT
A
Remove the rocker arms, rocker and shaft and bearing * Rear End
cap. (See Page 7B25.) Identification
Mark
Installation: Lubricate the camshaft lobes and bearing
journals before installing the camshaft. Tighten the
camshaft sprocket bolt to the correct torque [A].
* 3643 ft.lbs.
(4958 Nm)
B09770
Inspection
Check the camshaft journals for wear, scratches or
B
seizure. If the journal is excessively worn, replace the
camshaft.
Check the cam lobes for the correct specification [B].
Cam Lobe Height . . . . . . . . . . . . 1.4331 inch (36,4 mmj)
Service Limit . . . . . . . . . . . . . . 0.020 inch (0,5 mm)
Camshaft End Play . . . . . . . . . . . . . . . 0.0020.006 inch
(0,050,15 mm)
B09760
742B, 743B Loader

7B29 Service Manual
A
*
Apply Sealant to
both surfaces.
Do not apply
sealant.
* 5154 ft.lbs. (6973 Nm) Cold
# 1114 ft.lbs. (1519 Nm) B09769
CYLINDER HEAD
B
The tool will be needed to do the following procedure:
MEL1297 Head Bolt Tool
Remove the coolant from the coolant system.
Disconnect the radiator hose. Remove the spark plug
wires.
Remove the distributor. (See Page 7B5.)
Remove the fuel pump. (See Page 7B13.)
B09694
Remove the exhaust manifold.
Remove the intake manifold and carburetor. C Removing Head Bolt Sequence
Installation: Put sealant on both surfaces around the
water hole [A].
Remove the rocker arms, rocker shaft, bearing caps and
camshaft. (See Page 7B25.)
Use the special tool to remove the cylinder head bolts [B].
Remove the cylinder head bolts in the sequence shown

to prevent cylinder head warpage [C].
B09768
742B, 743B Loader

7B30 Service Manual
A Installing Head Bolt Sequence
Installation:
Tighten the bolts to 25 ft.lbs. (34 Nm) torque in the
sequence shown [A].
Tighten to 5154 ft.lbs. (6973 Nm) torque in the
sequence shown [A].
Remove the cylinder head. Remove the cylinder head
gasket.
Installation: Use a new cylinder head gasket and do not
B09767
use sealant on the gasket.
Inspection B
Clean the cylinder head of all carbon deposits. Remove
the valves. (See Page 7B32.)
Check the cylinder head surface by using a straight edge
in the direction of A, B, etc. [B].
Standard Dimension . . . . 0.002 inch (0,05 mm) or less
Service Limit . . . . . . . . . . . . . . . . . 0.004 inch (0,1 mm)
If the cylinder head surface exceeds the service limit,
either replace or grind the cylinder head.
B09764
742B, 743B Loader

7B31 Service Manual
VALVES 1
Removal
A 2
1 2
3
4 5
procedure: 5 6
6 7
MEL1296 Valve Stem Seal Installation
Remove the cylinder head from the engine block. (See 8
Page 7B30.)
Mark the valves so they will be returned to their original
position when assembled.
9
Remove the valve spring locks, using a spring
compressor [A].
Remove the spring retainer, spring, spring seat and valve 11
[A]. 10
13
12
1. Valve Stem Lock 8. Guide (Exhaust)

2. Retainer 9. Cylinder Head
3. Seal (Intake) 10. Exhaust Seal
4. Seal (Exhaust) 11. Intake Seat
5. Spring 12. Exhaust Valve
6. Spring Seat 13. Intake Valve
7. Guide (Intake) B09774
Remove the valve stem seals with a plier and discard [B].
Before reassembly, check the valves, valve seats and B
guides.
Installation
Make sure the cylinder head is clean.
Install the spring seal on the valve guide. Use the special
tool, install the valve stem seal into position. DO NOT turn
the seal when installing it.
The seal is installed in the specified position by the special
tool. Incorrect installation of the seal will affect the seal lip
I.D. and eccentricity, resulting in oil leakage down the B09766
valve guide.
Put oil on the valve stems and install. Install the valve
springs and spring retainer. Use a spring compressor and C
install the valve spring locks.
Tap the valve stem with a hammer a small amount to seal
the valve stem locks [C]. Stem Seal
Installer
B09765
742B, 743B Loader

7B32 Service Manual
VALVES (Contd)
A
Reconditioning The Valve And Valve Seat
Use the correct equipment to grind the valve and valve
seats.
The angle of the intake and exhaust valves is 45 [A].
Thickness
The valve head thickness is as listed [A].
Standard . . . . . . . . . . . . . . . . . . . . . . 0.059 inch (1,5 mm)
Service Limit . . . . . . . . . . . . . . . . . 0.039 inch (1,0 mm) 45
Check the valve stem tip for being pitted, correct the stem
tip by grinding. This must be limited to a minimum. B08202
Grind the valve seat, using a valve seat cutter (hand

operated) or grinding equipment [B]. B
B09762
Make sure the valve seat has the correct contact width
[C]. C Exhaust Intake
25 25
45 45
60 Contact width 60
(0.9 to1.3 mm
0,035 to 0,051 inch B09761
Valve Seat Inserts 0.0190.04 0.012

Remove the valve seat insert which has been worn out by
D (0,51,0 mm) 0.012 R (0,3 mm)
cutting down its wall thickness with a cutter as shown [D]. (0,3 mm) New
Hole
Machine the insert hole to the correct oversize with a
cutter or reamer as shown [D].
Heat the cylinder head to 120F. (50C.) and press fit the
oversize insert into the machined hole.
After installation, grind the insert to the correct angle and Cutting
check the depth of the valve [C]. Down
0.0190.04 0.006
(0,51,0 mm) (0,15 mm) B09914
742B, 743B Loader

7B33 Service Manual
VALVES (Contd)
Valve Guide
A 0.40 inch
(10 mm)
procedure:
MEL1298 Valve Guide Installation & Removal
Check the valve guides for wear with a dial indicator [A].
If the movement is more than listed specifications,
replace the valve guide.
Intake:
Standard . . . . . . . 0.00120.0024 inch (0,030,06 mm)
Service Limit . . . . . . . . . . . . . . . . 0.004 inch (0,15 mm) B08205
Exhaust:
Standard . . . . . . . 0.00200.0035 inch (0,050,09 mm)
Service Limit . . . . . . . . . . . . . . . . 0.006 inch (0,15 mm)
B
NOTE: Make sure to check the valve stem for wear
before replacing the valve guide.
Heat the cylinder head to a temperature of about 480F.

(250C.). Use the correct tool and press the valve guide
out of the cylinder head [B].
Check the SPECIFICATIONS Section 8 for the correct
oversize valve guide.
B09763
Ream each bore in the cylinder head to the correct size 0.5390.563
at normal temperature. Heat the cylinder head to about C (13,714,3 mm)
480F. (250C.) and quickly press the valve guide into
position using the correct special tool [C]. The correct
tool, ensures the guide is pressed in the specified depth.
B09732
Valve Spring
Check the free length and inclination of the exhaust and
D Inclination
intake springs [D].
New Free Length . . . . . . . . . . . . . 1.811 inches (46 mm)
Service Limit . . . . . . . . . . . . . . 0.039 inch (1,0 mm)
Inclination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5
Free Length
Service Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Square
B08208
742B, 743B Loader

7B34 Service Manual
VALVES (Contd)
Valve Spring (Contd)
A
Check the valve spring tension [A].
New Preload . . . . . . . . . . . . . . . . 29 lbs. @ 1.469 inches
(129 N @ 37 mm)
Used Preload . . . . . . . . . . . . . . . 83 lbs. @ 1.106 inches
(369 N @ 28 mm)
Service Limit . . . . . . . . . . . . . . 76 lbs. @ 1.106 inches
(338 N @ 28 mm)
B08209
The exhaust and intake valve springs are the same.

When installing the spring the colored portion (red or
green) is in the up position [B].
B
Identification Color:
NOTE:
Install with colored
portion up B09775
Check the valve seat insert depth [C].

If the depth exceed the service limit, replace the valve C
seat insert.
Installed Height of Spring:
Standard . . . . . . . . . . . . . . . . . . 1.469 inches (37,3 mm)
Service Limit . . . . . . . . . . . . . . +0.039 inch (+1,0 mm)
B09737
742B, 743B Loader

7B35 Service Manual
PISTON AND CONNECTING ROD
Removal
A
Remove the cylinder head. (See Page 7B30.)
Remove the oil pan. (See Page 7B51.)
Remove the ridge and carbon deposits at the top of the
cylinder bore with a ridge reamer.
Make sure the piston has identification marks [A].
Notch
Notch
B09778
Rotate the crankshaft until a pair of connecting rods are

at B.D.C. Make sure the connecting rod caps and the rods
have identification marks [B]. B
Remove the nuts and remove the caps.
NOTE: If the bearings are to be used again, they
must be marked so they will be returned to
their original location.
Use a hammer handle, push the piston and rod assembly

out of the engine block.
After the pair has been removed, rotate the engine
crankshaft and remove the other pair of pistons.
B09683
Disassembly
C
Remove the rings from the pistons [C].
To remove the piston pin from the connecting rod, a
special tool is needed (See Page 7B40 for the correct
procedure for Disassembly And Assembly.)
B08194
742B, 743B Loader

7B36 Service Manual
PISTON AND CONNECTING ROD (Contd)
Inspection
A
Clean all the parts in clean solvent.
Check the clearance of the new rings in the piston
grooves [A].
No. 1 Ring
Standard . . . . . . . 0.00120.0028 inch (0,030,06 mm)
No. 2 Ring
Standard . . . . . . . 0.00080.0024 inch (0,020,06 mm)
B09730
Check the ring gap in the cylinder bore [B].

No. 1 & 2 Ring End Gap:
B
Standard . . . . . . . . . . . . 0.0080.016 inch (0,20,4 mm)
Oil Ring Side Rail:
Standard . . . . . . . . . . . . 0.0080.020 inch (0,20,5 mm)
Service Limit . . . . . . . . . . . . . . . . . . 0.39 inch (1,0 mm)
B09729
Check the connecting rod alignment [C].

Connecting Rod Bend: C
Standard . . 0.0020/3.937 inches or less (0,05/100 mm)
B08232
Assembly
D
When assembling the piston and connecting rod, make
sure to align the marks on the piston and rod [D].
See Page 7B41 for the correct procedure to press the
piston pin into the connecting rod.
Front Mark
B09776
742B, 743B Loader

7B37 Service Manual
A Side Rail Gap
Assembly (Contd)
Install the piston rings on the piston in the following
sequence:
Install the three piece oil ring [A].
B09734
Install the No. 2 ring [B].

Chrome Plated
Install the No. 1 ring [B].
B
No. 1 Piston Ring
No. 2 Piston Ring
Oil Ring Side Rail
Chrome Plated
Spacer Expander B09735
Installation
Gap of Lower No. 1 Ring
NOTE: Make sure the piston ring gaps are C Side Rail Gap
positioned as illustrated [C].
Put oil around the piston and piston rings.

Using a ring compressor tool, compress the rings on the
piston. Front of
Engine
Make sure the mark is toward the front of the engine
block.
No. 2 Ring Gap

and Spacer Gap of Upper
Expander Gap Side Rail
B09733
Install the piston and connecting rod assembly [D].

D
B0337
742B, 743B Loader

7B38 Service Manual
Assembly (Contd)
A
Put oil on the bearings. Install the bearing cap [A].
B03208
Tighten the nuts to 2425 ft.lbs. (3334 Nm) torque [B]. B

Rotate the crankshaft to put the other pair of crankpins at
the bottom dead center. Repeat the procedure and install
the other pair of pistons.
2425 ft.lbs.
(3334 Nm)
B03325
742B, 743B Loader

7B39 Service Manual
PISTON PIN
A 4
Assembly Of The Tool 2
procedure:
MEL1286 Piston Pin Tool Set 1
Install the retaining ring (Item 1) [A] on the tube (Item 2)

[A] (MEL1290).
Drive or press the tube into the base (Item 3) [A]
3
(MEL1291).
Install the rear support (Item 4) [A] and wing nut
(MEL1289). B09695
NOTE: The rear support will have to be adjusted so

the piston and connecting rod assembly are
level in the anvil.
B
Install the anvil (Item 1) [B] on the tube (MEL1293).
Install the insert (Item 2) [B] on the anvil (MEL12941).
2
B09696
Removal Of The Piston Pin

Before pressing the old pin from the piston and
C
connecting rod assembly do the following, this will
correctly set up the tool:
Install the stop plug (MEL1287) into the tube [C].
B09898
Install the spring (MEL1288) (Item 1) [D], spacer

(MEL12943) (Item 2) [D] and pin guide (MEL1292) (Item
3) [D] into the tube.
D 3
B09677
742B, 743B Loader

7B40 Service Manual
PISTON PIN (Contd)
Removal Of The Piston Pin (Contd)
A
Install the old piston and connecting rod assembly on the
insert in the anvil. Make sure the insert goes between the
rod small end and piston. hold the piston down against
spring pressure.
Turn the stop plug inward until the pin guide (Item 1) [A]
just begins to lift the piston from the insert. Now the stop
plug is set for the correct distance when installing the new
piston pins.
Remove the pin guide, spacer and spring from the tube.
B09682
Install the piston and connecting rod assembly into the

anvil, make sure the insert (MEL12941) goes between
the rod small end and the piston [B].
B
B09697
Use the drive tool (MEL12942) (Item 1) [C] and press

the pin from the rod and piston.
C
Installation Of The Piston Pin
Install the spring, spacer and pin guide into the tube. The 1
pin guide, under spring pressure, will pas up through the
rod and piston in line until the new pin is installed.
Put oil on the piston pin before installing it into the piston
and rod.
B09679
Use the driver tool (MEL12942) (Item 1) [D], press the

pin (Item 2) [D] into the piston and connecting rod, until D
the spacer stops against the plug on the bottom of the
tube. Check to see if the pin is centered in the connecting 1
rod. Equal space at both sides of the piston pin.
NOTE: The piston must be free to move while
2
pressing the pin into position, check it
several times during installation of the piston
pin.
B09676
742B, 743B Loader

7B41 Service Manual
CYLINDER LINERS
A
Checking
Check the cylinder bore with an inside micrometer. the 0.5
checks must be made at parallel and right angles to the (90 mm)
0.35
center line of the bore [A]. (9 mm)
Measuring points are done approximately 0.35 inch (9
mm), 3.5 inches (90 mm) and 5.4 inches (137 mm) below
the top of the cylinder bore.
Standard . . . . . . . . . . . . . . . . . 3.0276 inches (76,8 mm)
OutOfRound and Taper: 5.4
Standard . . . . . . . . . . . . . 0.0008 inch (0,02 mm) or less (137 mm)
B09736
Piston to Cylinder Wall Clearance:
Standard . . . . . . . 0.00080.0016 inch (0,020,04 mm)
If the cylinder bores shown wear more than specified
outofround or taper or if the bores are badly scoffed or
scored, the cylinder block must be rebored and honed
to oversize and O/S pistons fitted.
Piston Service Size:
0.010 inch (0,25 mm) O.S.
0.020 inch (0,50 mm) O.S.
0.030 inch (0,75 mm) O.S.
0.039 inch (1,00 mm) O.S.
742B, 743B Loader

7B42 Service Manual
CRANKSHAFT AND MAIN BEARINGS
Description
A
The crankshaft has five main bearings. The end play is
controlled by a thrust bearing at the center main bearing.
Each main bearing cap has identification marks in relation Arrow Mark
to the engine block [A]. (Front of Engine)
The position of each cap can not be changed from the

original location.
Cap No.
View X B09777
Removal
Remove the timing cover and timing belt. (See Page
B
7B47.)
Remove the oil pan. (See Page 7B51.)
Remove the crankshaft rear oil seal and case [B].
B09754
Remove the main bearing caps and bearings [C].
NOTE: If the main bearings are going to be used

C
again, put a mark on them for correct
installation.
Remove the crankshaft.
B09740
Checking
Check the crankshaft connect rod journals [D]:
D
Standard . . . . . . . . . . . . . . . . . . . 1.7717 inches (45 mm)
OutofRound and Taper . . . . . . . . . . . . . . . 0.0004 inch
(0,01 mm) or less
Oil Clearance . . . 0.00040.0024 inch (0,010,06 mm)
B08244
742B, 743B Loader

7B43 Service Manual
CRANKSHAFT AND MAIN BEARINGS (Contd)
Checking (Contd)
A
Check the crankshaft main bearing journals [A]:
Standard . . . . . . . . . . . . . . . . . 2.244 inches (56,99 mm)
OutofRound and Taper . . . . . 0.0004 inch (0,01 mm)
or less
Oil Clearance . . . 0.00080.0028 inch (0,020,07 mm)
B08246
Checking Oil Clearance (Plastic Gauge)

Remove all the oil from the crankshaft bearing journals to
B
be checked.
Cut plastic gauge to the width of the bearing [B].
Install the bearing cap. Tighten the bolts to 3739 ft.lbs.
(5053 Nm) torque.
DO NOT turn the crankshaft.
Remove the bearing cap. Measure the width of the plastic
gauge [B].
If the clearance exceeds the limit, bearing must be
replaced or undersize used. B09739
Installation
C
Install the upper bearings in the engine block.
Put oil on the crankshaft journal.
Install the crankshaft.
Install the main bearing caps and tighten to specified
torque [C].
3739 ft.lbs.
(5053 Nm)
B03345
Starting at the center bearing cap and moving toward

each end of the crankshaft [D]. D Arrow
Mark
Cap No.
B09740
742B, 743B Loader

7B44 Service Manual
CRANKSHAFT AND MAIN BEARINGS (Contd)
Crankshaft End Play
A
The end play can be checked by either a feeler gauge [A]
or a dial indicator [B].
End Play . . . . . . . . . . 0.0020.007 inch (0,050,18 mm)
The fitting of oversize thrust bearing can be used to
correct the end play if it is over specifications.
B09728
B03291
Rear Oil Seal

The tool listed will be needed to do the following C Oil
Seal
Press
procedure:
MEL1300 Seal Installation Tool
Press the rear oil seal into the housing using the special
tool [C].
Put oil on the seal lip. Install the housing and rear seal on
the engine. Install the bolts and tighten.
B09738
742B, 743B Loader

7B45 Service Manual
TIMING BELT
A
Adjustment
It is not necessary to remove the timing belt covers for
adjustment.
Check and adjust the belt tension every 500 hours of
loader operation, use the following procedure:
Remove the shield from the engine.
Remove the plugs (two) in the cover for the timing belt [A].
B09851
Loosen the top nut and bottom bolt [B].

B
B09850
Put a screwdriver into the top hole and push on the belt
tensioner bracket to remove excessive slack from the
timing belt [C].
C
Tighten the bottom bolt after the slack has been removed
[C].
B09852
742B, 743B Loader

7B46 Service Manual
TIMING BELT (Contd)
Removal
A
Remove the crankshaft pulley (Item 1) [A].
Remove the upper timing belt cover (Item 2) [A].
Remove the lower timing belt cover (Item 3) [A].
Remove the crankshaft sprocket bolt (Item 4) [A].
4
1
3
B09759
Loosen the belt tensioner mounting nut [B].

Move the belt tensioner to loosen the timing belt [B]. B Water Pump
Remove the timing belt from the sprockets.
Nut
Tensioner
Timing
Bolt Belt B09758
Remove the crankshaft sprocket [C].

C
B09691
742B, 743B Loader

7B47 Service Manual
TIMING BELT (Contd)
A
Inspection
Flaw Conditions
Check the timing belt sprockets and tensioner for wear,
cracks or damage.
Back surface glossy. Nonelastic and so hard that
The surfaces of the oil pump sprocket and camshaft even if a fingernail is forced into it, no mark is
spacer which contact the oil seal must be checked for produced.
wear.
1.
Inspect the tensioner for easy and smooth rotation.
Check for end play and noise.
Check the belt for oil or dust deposits. The slight deposits
must be cleaned with cloth or paper. DO NOT use solvent
to clean the timing belt.
2.
Check the timing belt in detail for the following conditions,
replace as needed [A].
1. Hardened back surface rubber. Crack Crack
2. Cracked back surface rubber.
3.
3. Cracked or exposed canvas.
Separation Separation
4. Badly worn teeth (initial stage).
Canvas on load side tooth flank worn. Fluffy
5. Badly worn teeth (last stage). canvas fibers, rubber gone and color changed to
white, and unclear canvas texture.
6. Cracked tooth bottom.
4.
7. Missing tooth.
8. Side of belt badly worn.

Canvas on load side tooth flank worn down and
9. Side of belt cracked. rubber exposed (tooth width reduced).
5.
6.
Crack
Tooth missing
and canvas
fiber exposed
7.
NOTE: Normal belt should have clearcut sides as

if cut by a sharp knife.
Round
8. Belt Side
Abnormal wear
(fluffy canvas fiber)
9.
B09751
742B, 743B Loader

7B48 Service Manual
TIMING BELT (Contd)
A
Assembly
Install the crankshaft sprocket [A].
Tighten the bolt to 4450 ft.lbs. (6068 Nm) torque.
B09691
Align timing mark on the crankshaft sprocket with the

timing mark on the front case [B]. B
Put a small amount of oil on the outside of the camshaft
spacer and install the spacer on the camshaft.
Install the camshaft sprocket. Tighten the bolt to 4457
Timing Mark
B09752
Align the camshaft timing mark with the mark on the upper
Upper Under
cover [C]. C Cover Timing
Mark
Camshaft
Sprocket Dowel
Pin
B09755
Install the spring and tensioner, and temporarily tighten

the nut [D]. Spring
D
Push the flange, located under the tensioner, to make Tensioner
alignment of the holes (Items 1 & 2) [D]. Install the bolts
into the holes.
Install the front end of the spring (bent at right angle) on
the projection of the tensioner.
Install the spring
end at this position
Install the other end (straight end) on the water pump
of the water pump
body [D]. body.
1 2
B09750
742B, 743B Loader

7B49 Service Manual
TIMING BELT (Contd)
A Water Pump
Assembly (Contd)
Install the timing belt, use the following procedure:
Put the belt on the crankshaft sprocket. Nut
Install on the oil pump sprocket.

Then on the camshaft sprocket.
Make sure that all the timing marks are in alignment. Tensioner
Move the belt tensioner to apply pressure to the belt [A].
Timing
Bolt Belt B09758
NOTE: Do not turn the crankshaft in a reverse
direction. DO NOT push or twist the belt or try
to test the tension. This will result incorrect
belt tension. B
Push the tensioner, with your hand a small amount to
make sure the belt comes in complete mesh with the
sprockets. If this is neglected and the belt tension
adjusted with the belt out of mesh with the sprocket (Item
1) [B], the belt tension will not be correct.
1
Turn the engine through one revolution in normal
direction, to remove all slack at the timing belt.
Tensioner
B09757
Tighten the tensioner mounting nut first and then the bolt
[C]. C
Tighten the nut and bolt to 1621 ft.lbs. (2228 Nm)
torque.
B09753
Check the tension side of the timing belt, the clearance

between the belt and the seal line is 0.470 inch (12 mm)
[D].
D
If specifications are not correct, readjust the belt.
0.470
(12 mm)
B09756
742B, 743B Loader

7B50 Service Manual
FRONT CASE AND OIL PAN
A
The front case contains the oil pump and relief valve and
can be removed as an assembly.
Remove the front cover and timing belt. (See Page
7B47.)
Remove the engine oil.
Remove the oil pan bolts (Item 1) [A].
Installation: Tighten the bolts to 5466 in.lbs. (6,17,5
Nm) torque.
Remove the oil pan and oil screen.
Installation: Tighten the oil screen nuts to 1318 ft.lbs.
(1824 Nm) torque (Item 2) [A].
Remove the bolts from the front case [A].
The front case is held closely to the engine block, it may 2
be hard to loosen. Insert a screwdriver into the groove and
pry. Avoid prying on the thinner portion of the flange.
B09772
Installation: Install the front case bolts according to the

L=length of bolt
correct length [B]. Tighten the bolts to 1113 ft.lbs.
(1518 Nm) torque.
B L=0.98 (25 mm)
L=0.79 L=1.57
(20 mm) (40 mm)
L=0.98
(25 mm) L=1.57 (40 mm) B09773
When installing the oil pan, apply sealant to the four areas
Oil Seal
shown [C]. C Case
NOTE: For inspection of the oil pump. (See Page
7B52 for the specifications.)
Front
Case
Cylinder Block
B09747
742B, 743B Loader

7B51 Service Manual
OIL PUMP
A
Removal
Remove the timing cover and timing belt. (See Page
7B47.)
Remove the oil pump sprocket, use the following
procedure:
Use an old timing belt and put it around the oil pump
sprocket to hold it. DO NOT use a screwdriver.
Loosen the nut at the sprocket.
Remove the timing belt and sprocket.
B09745
Remove the pump bolts at the oil pump.
Body Clearance
Slide the oil pump assembly away from the front case [A]. B Side
Clearance Tip
Remove the rotor from the oil pump cover.
Clearance
Inspection
Use a feeler gauge to check the clearances as listed [B]:
Tip Clearance . . . . 0.00160.0047 inch (0,40,12 mm)
Body Clearance . 0.00390.0063 inch (0,100,16 mm)
Side Clearance . 0.00080.0020 inch (0,020,05 mm)
ShafttoCover Clearance . . . . . . . . 0.00080.002 inch
(0,020,05 mm) Shafttocover
Clearance
B09742
Installation
Install a new cover gasket in the front case [C]. Install the
C
gasket with the round edge toward the oil pump cover.
Front Case
Sectional
Form of
Gasket Gasket
B09746
Use a flat plate, install the oil seal using a press until it is
flush with the front edge of the oil pump cover [D]. Flat Iron Plate
D
Oil Pump Cover Oil Seal
B09741
742B, 743B Loader

7B52 Service Manual
OIL PUMP (Contd)
A
Install the inner and outer rotor in the oil pump cover, after
putting oil on the surface of the rotors.
The inner rotor and outer rotor have a mark on them,
install the rotors with the marks in the same direction [A].
Marks
B09743
Slide the oil pump assembly into the front cover [B].
B
B09745
Install the 0.24 inch (6 mm) diameter bolt (Item 1) [C].

Install the other bolts and tighten to 1113 ft.lbs. (1518 C
Nm) torque.
Tighten the bolt (Item 1) [C] to 90102 in.lbs. (10,211,5
Nm) torque.
Put a small amount of oil on the oil seal.
Install the sprocket for the oil pump.
Put an old timing belt around the sprocket to hold it and
tighten the nut to 2528 ft.lbs. (3438 Nm) torque.
Install the timing belt and front cover. (See Page 7B48.)
1
B09773
Relief Valve
D
Remove the oil pressure relief valve [D].
Check the poppet for damage. Check the spring for free
length and preload as listed below:
Free Length . . . . . . . . . . . . . . . . . 1.850 inches (47 mm)
Preload . . 16 lbs. @ 1.398 inches (71 N @ 35,5 mm)
If spring is not within specifications, replace the spring.
B09699
742B, 743B Loader

7B53 Service Manual
FRONT CASE SEAL
A
procedure:
MEL1301 Front Crankshaft Seal Installation Tool
Remove the crankshaft pulley, timing belt covers and
timing belt. (See Page 7B47.)
Remove the bolt at the crankshaft sprocket [A].
Installation: Tighten the bolt to 3643 ft.lbs. (4958
Nm) torque.
B09705
Remove the crankshaft sprocket.
Drill a hole into the front seal [B]. B
Be careful not to damage the front case surface behind
the seal with the drill.
B09690
Use a slide hammer puller, remove the front seal [C].

C
B09692
Use the installation tool, install the front seal [D].

Install guide over camshaft and key way (MEL13011). D
Install seal over the guide.
Using the driver, install the seal into the front housing
(MEL13012).
B09689
742B, 743B Loader

7B54 Service Manual
WATER PUMP
A
Drain the coolant from the cooling system.
Remove the alternator belt.
Remove the crankshaft pulley, timing belt covers, timing
belt, camshaft sprocket and belt tensioner. (See page
7B47.)
Remove the four water pump bolts [A].
B09687
Slide the water pump to the side and remove it from the
engine block [B]. B
B09688
Installation: Make sure the correct length bolt is in the

L=Length of Bolt
correct location [C]. Tighten the bolts to 1113 ft.lbs.
(1518 Nm) torque. C
L=2.75
(70 mm)
Inspection L=2.10
(28 mm)
Check each part for cracks, damage or wear and replace
the water pump assembly if necessary.
L=2.17
(55 mm)
B09779
Check the bearing for damage, noise and slow rotation

[D]. From Radiator
D
Check the seal for leaks and replace the water pump Cylinder Block
assembly if necessary.
Pulley Bracket
Impeller
To Water Jacket
Of Engine
Water
Shaft Assembly Pump Body
Seal Unit B09744
742B, 743B Loader

7B55 Service Manual
THERMOSTAT
742B,743B Service Manual #6720772 (S/N 18001 & Above) Engine System Section Part 5 of 5

A
The thermostat is of the wax type, valve cracking
temperature is not affected by pressure in the water
jacket. The jiggle valve removes air from the system
during filling the cooling system and to reduce the
warmup time.
Drain the cooling system.
Remove the radiator hose at the thermostat housing.
Remove the bolts from the housing [A].
B09702
Remove the housing and the thermostat [B].

B
Inspection
Put the thermostat in a container filled with water. Heat
the water. Measure the temperature at which the valve
cracks and the valve lift is fully open.
Cracking Temperature . . . . . . . . . . . . . . 179 F. (82 C.)
0.315 inch (8 mm)
Lift Temperature . . . . . . . . . . . . . . . . . . . . 203 F. (95 C.)
If the thermostat is not within specifications, replace the
thermostat.
B09703
742B, 743B Loader

7B56 Service Manual
SPECIFICATIONS
Page
Number
743B LOADER SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A1
742B LOADER SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8B1
TECHNICAL DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8C1
SPECIFICATIONS
743B
742B
TECHNICAL
DATA
742B, 743B Loader

8A3 Service Manual
SPECIFICATIONS (743B)
Page
Number
ENGINE SPECIFICATIONS
Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A3
Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A4
Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A4
Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A3
Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A4
Engine Bolt Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A5
Fuel Injection Nozzles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A3
Fuel Injection Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A3
Pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A4
Piston Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A4
Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A4
Rocker Arms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A3
Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A3
Valve Springs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A3
LOADER SPECIFICATIONS
Drive System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A2
Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A2
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A1
Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A2
Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A2
Loader Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A1
Operation And Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A1
Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A2
743B
742B, 743B Loader

8A1 Service Manual
743B LOADER SPECIFICATIONS Dimensions are given for loader equipped with standard tires and dirt bucket.
Dimensions may vary with other types. All dimensions are shown in inches. Respective
metric dimensions are given in millimeters enclosed by parentheses.
LOADER DIMENSIONS Where applicable, specifications conform to SAE standards and are subject to change
without notice.
55.1
139.6 (1400)
100
(3546)
69.7
(1770)
37
44.2
(1123)
21.8 109
(554) (2769)
75.8 35.7 86.3

(1925) (907) (2192)
58.5
32.3 (1486)
28 (820)
26
7.5 8.0 47.0
(191) 35.4 (203) (1194)
(899) 54.0
94.5 (1372)
(2423)
120.4 PI2206
(3058)
This loader was designed without counterweights or ballasts. Changes of structure or weight distribution of the
loader can cause changes in control and steering response and can cause failure of the loader parts.
743B
OPERATIONS & PERFORMANCE
Weights
Operating Weight . . . . . . . . . . . . . . . . . . . 4720 lbs. (2188 kg)
Rated Operating Capacity . . . . . . . . . . . . 1300 lbs. (590 kg)
Tipping Load . . . . . . . . . . . . . . . . . . . . . . . 2600 lbs. (1180 kg)
Travel Speed . . . . . . . . . . . . . . . . . . . . . . . . Infinitely variable 06.0 MPH (9,7 km/hr.)
Controls
Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . Direction & speed controlled by two hand levers.
Loader Function . . . . . . . . . . . . . . . . . . . . Lift & Tilt Function: Controlled by separate foot pedals.
Front Auxiliary Function: Controlled by the right steering lever.
Engine Hand lever throttle & keytype starter switch;
Main Drive . . . . . . . . . . . . . . . . . . . . . . . . . Hydrostatic
Parking Brake . . . . . . . . . . . . . . . . . . . . . . Mechanical disc, foot operated pedal
ENGINE
Make . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Kubota
Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V1702BA
Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Diesel
Horsepower . . . . . . . . . . . . . . . . . . . . . . . . 36 HP (27 kW)
Maximum Governed RPM . . . . . . . . . . . . 2800 RPM
Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 ft.lbs. (108 Nm) @ 1600 RPM
Number of Cylinders . . . . . . . . . . . . . . . . . Four
Bore/Stroke . . . . . . . . . . . . . . . . . . . . . . . . 3.23/3.23 (82/82)
Displacement . . . . . . . . . . . . . . . . . . . . . . . 105.7 cu. in. (1732 cm )
Cooling System . . . . . . . . . . . . . . . . . . . . . Liquid
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . Full pressure with full flow filter
Crankcase Ventilation . . . . . . . . . . . . . . . . PCV
Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . Dry replaceable paper cartridge
Ignition . . . . . . . . . . . . . . . . . . . . . . . . . . . . Compression Diesel
High Idle . . . . . . . . . . . . . . . . . . . . . . . . . . . 28603000 RPM
Low Idle . . . . . . . . . . . . . . . . . . . . . . . . . . . 1150 RPM
742B, 743B Loader

LOADER SPECIFICATIONS (Contd) 743B
HYDRAULIC SYSTEM
Hydraulic Pump . . . . . . . . . . . . . . . . . . . . . Engine driven gear type
Pump Capacity . . . . . . . . . . . . . . . . . . . . . 12.1 GPM (45,8 L/min.) @ 2500 RPM
System Main Relief . . . . . . . . . . . . . . . . . . 22502400 PSI (1551316548 kPa)
Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replaceable #3 micron paper element in charge line
Hydraulic Cylinders . . . . . . . . . . . . . . . . . . . Doubleacting
Bore Diameter:
Lift Cylinder (2) .................... 2.00 (51)
Tilt Cylinder (1) .................... 3.25 (83)
Rod Diameter:
Lift Cylinder (2) .................... 1.25 (32)
Tilt Cylinder (1) .................... 1.50 (32)
Stroke:
Lift Cylinder (2) .................... 25.00 (635)
Tilt Cylinder (1) .................... 14.5 (368)
Control Valve . . . . . . . . . . . . . . . . . . . . . . . 3spool, open center type, W/float detent on lift, detent on auxiliary
Fluid Lines . . . . . . . . . . . . . . . . . . . . . . . . . SAE standard tubes, hoses & fittings
Hydraulic Function Time:

Raise Lift Arms to Maximum Height . . . . 3.5 Seconds
Lower Lift Arms from Maximum Height . 2.7 Seconds
Move Bucket to Dump Position . . . . . . . . 2.7 Seconds
Move Bucket to Retracted Position . . . . 2.3 Seconds
Fluid Type . . . . . . . . . . . . . . . . . . . . . . . . . . . Bobcat Fluid (P/N 6563328). If fluid is not available use 10W30 or 10W40
Class SE Motor Oil for temperatures above 0_F (18_C) & 5W30 for
temperatures below 0_F (18_C)
ELECTRICAL
Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . Belt drive, 55 amps. Open
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 volt, 625 cold crank amps. @ 0F (17.8C) 125 min. reserve capacity
Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 volt
DRIVE SYSTEM
Transmission . . . . . . . . . . . . . . . . . . . . . . . Tandem hydro. pumps driving 2 fully reversing hydro. motors
Final Drive . . . . . . . . . . . . . . . . . . . . . . . . . #80 HS roller chain & sprockets in sealed chaincase with oil lubrication
CAPACITIES
Cooling System . . . . . . . . . . . . . . . . . . . . . 13 qts. (12 L)
Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 gals. (49 L)
Engine Oil W/Filter . . . . . . . . . . . . . . . . . . 9 qts. (8,5 L)
Hydraulic/Hydrostatic System . . . . . . . . . 6 gals. (23 L) (Includes 3.5 gals [13,2 L] in reservoir)
Chaincase Reservoir . . . . . . . . . . . . . . . . 8 gals. (30,3 L)
TIRES
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . 7:00 x 15, 6Ply Rating
Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . 4550 PSI (310345 kPa)
Flotation . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 x 16.5, 6 Ply Rating
Pressure . . . . . . . . . . . . . . . . . . . . . . . . . 3035 PSI (207241 kPa)
742B, 743B Loader

8A2 Service Manual
All dimensions are given in inches. Respective metric dimensions are given in millimeters enclosed by parentheses.
Fuel Injection Nozzles
Opening Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19902130 PSI (1372114686 kPa)

Fuel Tightness Nozzle Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dry Nozzle at 18481990 PSI (1274213721 kPa)
Fuel Injection Pump
Fuel Tightness Plunger . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 sec: initial pressure from 85327110 PSI (5882849023 kPa)
Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 seconds or less
Fuel Tightness of Delivery Valve . . . . . . . . . . . . . . . . . . . . . . . . 10 sec: initial pressure from 142271 PSI (9805490 kPa)
Limited Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 seconds or less
Injection Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2526 degrees before TDC
High Idle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28603000 RPM
Low Idle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7001000 RPM
Cylinder Head
Cylinder Head Surface Distortion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.002 (0,05)

Thickness of Gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.057 (1,45)
Thickness of Gasket Shim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0059 or 0.0079 (0,15 or 0,2)
Top Clearance (Piston to Head) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.02760.0354 (0,70,9)
Head Bolt Torque
Flange Head Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6568 ft.lbs. (8892 Nm)
Bolt W/Washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5868 ft.lbs. (7983 Nm)
Maximum Allowable Milling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.004 (0,1)
Valves
Valve Seat Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0827 (2,1)

Valve Seat Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 degrees
O.D. of the Valve Stem (Intake and Exhaust) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.31340.3140 (7,9607,975)
I.D. of the Valve Guides (Intake and Exhaust) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.31560.3161 (8,0158,030)
Clearance Between Valve Stem & Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.00160.0028 (0,040,07)
Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0039 (0,1)
Depth of Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.04330.0512 (1,11,3)
Valve Clearance (Cold) (Intake and Exhaust) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.00710.0087 (0,180,22)
Valve Springs
Free Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.64171.6614 (41,742,2)

Fitted Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3839 (35,15)
Load to Compress to Fitted Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26.5 lbs. (118 N)
Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22.5 lbs. (100 N)
Rocker Arms
O.D. of Rocker Arm Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.55010.5506 (13,97313,985 )

I.D. of Rocker Arm Bushings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.55130.5529 (14,00314,043)
Clearance Between Rocker Arm & Bushings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.00040.0028 (0,010,07)
Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0059 (0,15)
Camshaft
O.D. of Camshaft Bearing Journal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.57221.5728 (39,934329,9 )

I.D. of Camshaft Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.57481.5758 (40,040,025)
Clearance Between Camshaft Journal & Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0020.0036 (0,50,091)
Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0059 (0,15)
Alignment of the Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.008 (0,02)
Cam Lobe Height (Intake and Exhaust) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3134 (33,31)
Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3114 (33,31)
Gear Clearance (Backlash) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.00160.0045 (0,0410,114)
Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0118 (0,3)
742B, 743B Loader

8A3 Service Manual
ENGINE SPECIFICATIONS (Contd)
Cylinders
I.D. of Cylinder Liner (Std.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.22833.2291 (82,082,019)
Oversized Liner I.D. (After Reboring .020 O/S) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2483.2489 (82,49982,522)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0059 (0,15)
Piston Rings
Ring Gap (Top and 2nd Ring) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.01180.0177 (0,300,45)
Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0492 (1,25)
Ring Gap (Oil Ring) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.009800.0157 (0,250,40)
Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0492 (1,25)
Side Clearance of Ring in Groove
Top Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 Clearance
2nd Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.00370.0047 (0,0930,120)
Oil Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.00080.0020 (0,0200,051)
Pistons
I.D. of Piston Bosses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.90550.9060 (2323,013)
Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.9076 (23,053)
O.D. of Piston Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.90560.9059 (23,00223,011)
I.D. of Connecting Rod Bushing (Small End, Fitted) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.90650.9071 (23,02523,04)
Clearance Between Piston Pin & Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.00060.0015 (0,0150,038)
Service Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.00060.0026 (0,0150,07)
Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0059 (0,15)
Connecting Rod Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.008 (0,02)
Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.002 (0,05)
Connecting Rod Big End I.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (W/O Bearing) 1.8501.851 (47,047,02)
Crankshaft
O.D. Main Bearing Journals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.04412.0449 (51,9251,94)
I.D. of Crankshaft Main Bearing (No. 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.04652.0488 (51,9852,039)
I.D. of Crankshaft Main Bearing (No. 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.04652.0482 (51,9852,025)
Clearance Between Crankshaft Journal & Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.00130.0042 (0,030,11)
Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0079 (0,2)
O.D. of Connecting Rod Journals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.73071.7313 (43,95943,975)
I.D. of Connecting Rod Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.73271.7343 (44,0144,052)
Clearance Between Connecting Rod Journal & Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.00140.0037 (0,0350,093)
Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0079 (0,2)
End Play of Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.00590.080 (0,150,21)
Thrust Plate Thickness:
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0910.093 (2,312,36)
Oversize . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.09350.0955 (2,372,43)
0.0960.098 (2,442,49)
0.09850.1005 (2,502,55)
0.1010.103 (2,572,62)
Crankshaft Journal U/S (Dia.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.03632.037 (51,7251,74)
2.02842.0291 (51,5251,54)
Oil Pump
Oil Pressure @ Rated RPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4256 PSI (290386 kPa)
Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 PSI (248 kPa)
Rotor Lobe Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.00390.0063 (0,100,16)
Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0079 (0,20)
Clearance Between Outer Rotor & Pump Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.00430.0075 (0,110,19)
Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0098 (0,25)
Engine Oil
Check oil level every 8 hours of operation. (Check oil every 4 hours on new engine during the first 50 hours of operation.)
Oil level must be between the add and full marks on the dipstick. Use a good quality detergent motor oil that meets the
correct API service classification. (See Chart of Page 8A5.)
Use oil of the correct SAE viscosity for expected temperature conditions.
742B, 743B Loader

8A4 Service Manual

C34 29 23 18 13 7 1 +4 +10 +15 +21 +27 +32 +38 +43 +49 +54 +60
SAE 40 or 20W50
Never overfill the engine crankcase with oil.

SAE 10W30
I21250597
SAE 15W40
SAE 5W30
SAE 30W
SAE 20W20
SAE 10W
F30 20 10 0 +10 +20 +30 +40 +50 +60 +70 +80 +90 +100 +110 +120 +130 +140

NEXT OIL CHANGE
(GASOLINE: USE API CLASSIFICATION SE or SF)
(DIESEL: USE API CLASSIFICATION CC, CD or CE)
ENGINE BOLT TORQUES

Bolt material grades are shown by numbers punched on the bolt heads.
Before tightening, check the numbers shown below:
NOTE: Special bolts are used where required. Please refer to Assembly Section for correct special bolt torque.
Ft.Lbs. Nm
Fuel injector Pump Mounting Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1720 2327

Hydrostatic Pump Adapter Flange to Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . 1517 2023
Engine Mounting Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6570 8895
Oil Pump to Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 6,88,1
Gearcase Cover Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1315 1820
Flywheel Housing Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2528 3438
Hydrostatic Pump to Flywheel Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6570 8895
Nozzle Holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2236 3049
Flywheel to Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7280 98108
Pulley to Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101110 137149
Water Pump Shaft Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5057 6878
Crankshaft Rear Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1317 1720
Valve Cover Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 6,88,1
Connecting Rod Caps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2630 3541
Bearing Case Bolt (1) Through Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4750 6468
Bearing Case Halves 2 Bolts Each . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2125 2834
Camshaft Mounting Flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1315 1820
742B, 743B Loader

8A5 Service Manual
742B(S/N509418001&Above),743B(S/N509318001&Above)ServiceManual#6720772SpecificationsSectionPart1of3
Engine Bolt Torques (Contd)
BOLT TORQUES
MATERIAL GRADE STANDARD BOLT SPECIAL BOLT SPECIAL BOLT
NOMINAL DIAMETER SS42, S20C S43C, S48C (Refined) SCR3, SCM3 (Refined)
M6 5.8 to 6.9 ft.lbs. 7.2 to 8.3 ft.lbs. 9.0 to 10.5 ft.lbs.
(7.8 to 9.3 Nm) (9.8 to 11.3 Nm) (12.3 to 14.2 Nm)
M8 13 to 15 ft.lbs. 17 to 20 ft.lbs. 21 to 25 ft.lbs.
(18 to 20 Nm) (23 to 27 Nm) (28 to 34 Nm)
(38 to 45 Nm) (47 to 56 Nm) (60 to 71 Nm)
(62 to 72 Nm) (77 to 89 Nm) (102 to 117 Nm)
(107 to 125 Nm) (123 to 146 Nm) (167 to 195 Nm)
(167 to 191 Nm) (195 to 225 Nm) (159 to 303 Nm)
(244 to 283 Nm) (274 to 318 Nm) (343 to 401 Nm)
332 to 392 Nm) (367 to 431 Nm) (489 to 568 Nm)
742B, 743B Loader

8A6 Service Manual
SPECIFICATIONS (742B)
Page
Number
Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8B7
Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8B4
Carburetor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8B6
Connecting Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8B4
Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8B4
Cylinder Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8B3
Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8B3
Distributor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8B7
Engine Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8B7
Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8B4
Fuel Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8B6
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8B3
Piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8B3
Piston Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8B3
Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8B6
Rocker Arm & Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8B6
Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8B7
Spark Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8B7
Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8B6
Valve Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8B5
Valve Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8B5
Valve Train . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8B4
Water Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8B6
LOADER SPECIFICATIONS
Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8B2
Drive System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8B2
Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8B1
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8B2
Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8B2
Loader Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8B1
Operation And Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8B1
Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8B2
742B
742B, 743B Loader

8B1 Service Manual
742B BOBCAT LOADER Dimensions are given for loader equipped with standard tires and dirt bucket.
Dimensions may vary with other types. All dimensions are shown in inches. Respective
metric dimensions are given in millimeters enclosed by parentheses.
LOADER DIMENSIONS Where applicable, specifications conform to SAE standards and are subject to change
without notice.
55.1
139.6 (1400)
100 (3546)
69.7
(1770)
109
37 (2769) 44.2
(1123)
21.8
(554)
75.8 86.3
35.7 (2192) 58.5
(1925) (907) (1486)
32.3
(820)
28 26
8.0 47.0
7.5 35.4 (1194)
(191) (203) 54.0
(899) (1372)
94.5
(2423)
120.4
(3058) B12596
This loader was designed without counterweights or ballasts. Changes of structure or weight distribution of the
loader can cause changes in control and steering response and can cause failure of the loader parts.
OPERATIONS & PERFORMANCE

742B
Weights
Operating Weight . . . . . . . . . . . . . . . . . . . 4830 lbs. (2193 kg)
Rated Operating Capacity . . . . . . . . . . . . 1300 lbs. (590 kg)
Tipping Load . . . . . . . . . . . . . . . . . . . . . . . 2600 lbs. (1180 kg)
Travel Speed . . . . . . . . . . . . . . . . . . . . . . . . Infinitely variable 06.0 MPH (9,7 km/hr.)
Controls
Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . Direction & speed controlled by two hand levers.
Loader Function . . . . . . . . . . . . . . . . . . . . Lift & Tilt Function: Controlled by separate foot pedals.
Front Auxiliary Function: Controlled by the right steering lever.
Engine Hand lever throttle & keytype starter switch;
Main Drive . . . . . . . . . . . . . . . . . . . . . . . . . Hydrostatic
Parking Brake . . . . . . . . . . . . . . . . . . . . . . Mechanical disc, foot operated pedal
ENGINE
Make . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Mitsubishi
Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4G32
Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gasoline, leaded or unleaded
Horsepower . . . . . . . . . . . . . . . . . . . . . . . . 36 HP (27 kW)
Maximum Governed RPM . . . . . . . . . . . . 2800 RPM
Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 ft.lbs. (99 Nm) @ 2000 RPM
Number of Cylinders . . . . . . . . . . . . . . . . . Four
Bore/Stroke . . . . . . . . . . . . . . . . . . . . . . . . 3.03/3.38(76,9/85,8)
Displacement . . . . . . . . . . . . . . . . . . . . . . . 95.62 cu. in. (1567 cm3 )
Cooling System . . . . . . . . . . . . . . . . . . . . . Liquid
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . Full pressure with full flow filter
Crankcase Ventilation . . . . . . . . . . . . . . . . PCV
Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . Dry replaceable paper cartridge
Ignition . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 volt, battery ignition W/breaker points & coil
High Idle . . . . . . . . . . . . . . . . . . . . . . . . . . . 29002975 RPM
Low Idle . . . . . . . . . . . . . . . . . . . . . . . . . . . 850950 RPM
742B, 743B Loader

Revised Sept. 93 8B1 Service Manual
LOADER SPECIFICATIONS (Contd) 742B
HYDRAULIC SYSTEM
Hydraulic Pump . . . . . . . . . . . . . . . . . . . . . Engine driven gear type
Pump Capacity . . . . . . . . . . . . . . . . . . . . . 12.1 GPM (45,8 L/min.) @ 2500 RPM
System Main Relief . . . . . . . . . . . . . . . . . . 22502400 PSI (1551416548 kPa) @ Quick Couplers
Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replaceable #3 micron paper element in charge line
Hydraulic Cylinders . . . . . . . . . . . . . . . . . . . Doubleacting
Bore Diameter:
Lift Cylinder (2) .................... 2.00 (51)
Tilt Cylinder (1) .................... 3.25 (83)
Rod Diameter:
Lift Cylinder (2) .................... 1.25 (32)
Tilt Cylinder (1) .................... 1.50 (32)
Stroke:
Lift Cylinder (2) .................... 25.00 (635)
Tilt Cylinder (1) .................... 14.5 (368)
Control Valve . . . . . . . . . . . . . . . . . . . . . . . 3spool, open center type, W/float detent on lift, detent on auxiliary
Fluid Lines . . . . . . . . . . . . . . . . . . . . . . . . . SAE standard tubes, hoses & fittings
Hydraulic Function Time:

Raise Lift Arms to Maximum Height . . . . 3.5 Seconds
Lower Lift Arms from Maximum Height . 2.7 Seconds
Move Bucket to Dump Position . . . . . . . . 2.7 Seconds
Move Bucket to Retracted Position . . . . 2.3 Seconds
Fluid Type . . . . . . . . . . . . . . . . . . . . . . . . . . . Bobcat Fluid (P/N 6563328). If fluid is not available use 10W30 or 10W40
Class SE Motor Oil for temperatures above 0_F (18_C) & 5W30 for
temperatures below 0_F (18_C)
ELECTRICAL
Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . Belt drive, 55 amps. Open
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 volt, 435 cold crank amps. @ 0F (17.8C) 125 min. reserve capacity
Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 volt
DRIVE SYSTEM
Transmission . . . . . . . . . . . . . . . . . . . . . . . Tandem hydro. pumps driving 2 fully reversing hydro. motors
Final Drive . . . . . . . . . . . . . . . . . . . . . . . . . #80 HS roller chain & sprockets in sealed chaincase with oil lubrication
CAPACITIES
Cooling System . . . . . . . . . . . . . . . . . . . . . 11 qts. (10,4 L)
Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 gals. (49 L)
Engine Oil W/Filter . . . . . . . . . . . . . . . . . . 4 qts. (3,8 L)
Hydraulic/Hydrostatic System . . . . . . . . . 6 gals. (23 L) (Includes 3.5 gals [13,2 L] in reservoir)
Chaincase Reservoir . . . . . . . . . . . . . . . . 8 gals. (30,3 L)
TIRES
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . 7:00 x 15,6 Ply Rating
Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . 4550 PSI (310345 kPa)
Flotation . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 x 16.5, 6 Ply Rating
Pressure . . . . . . . . . . . . . . . . . . . . . . . . . 3035 PSI (207241 kPa)
742B, 743B Loader

8B2 Service Manual
General
Compression PSI @ 250 RPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150 PSI (1034 kPa)

Difference between Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Within 10%
Ignition Timing (BTDCwith Vacuum Line Off) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 @ 700750 RPM
Cylinder Head
Flatness of Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.002 (0,05) or less

Flatness of Manifold Mounting Surface Service Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.012 (0,3)
Oversize Valve Seat Hole
Intake 0.012 (0,3) O.S. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5471.548 (39,2939,32)
0.024 (0,6) O.S. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5591.560 (39,6039,62)
Exhaust 0.012 (0,3) O.S. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3501.351 (34,3034,32)
0.24 (0,6) O.S. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3621.363 (34,6034,62)
Camshaft cap to Camshaft Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0020.004 (0,050,10)
Service Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.006 (0,15)
Valve Guide Hole Oversize (Both Intake & Exhaust)
0.002 (0,05) O.S. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.51380.5145 (13,0513,068)
0.010 (0,25) O.S. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.52160.5224 (13,2513,268)
0.020 (0,50) O.S. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.53150.5322 (13,5013,518)
Valve Seat Contact Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0350.051 (0,91,3)
Valve Seat Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Cylinder Block
Flatness of Cylinder Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.002 (0,05) or less

Cylinder Bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.276 (76,90)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.008 (0,20)
Service Limit (Maximum Oversize) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . +0.047 (+1,2)
Cylindrical Within Bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0004 (0,01) or less
Cylinder to Piston Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.00080.0016 (0,020,04)
Piston
Piston O.D. @ Skirt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.0276 (76,90)

Piston Pin Hole I.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.748 (19,0)
Piston O.S. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.010 (0,25); 0.020 (0,50); 0.030 (0,75); 0.039 (1,0)
Piston Ring to Groove Clearance
Compression No. 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.00110.0027 (0,30,07)
Service Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.006 (0,15)
Compression No. 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.00080.0024 (0,020,06)
Service Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.006 (0,15)
Compression Ring Gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.00980.0177 (0,250,45)
Service Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.039 (1,0)
Oil Ring Gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.00080.028 (0,20,7)
Service Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.039 (1,0)
Piston Ring O.S. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.010 (0,25); 0.020 (0,50); 0.030 (0,75); 0.039 (1,0)
Piston Pin
Piston Pin O.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.748 (19,)

Piston to Piston Pin Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.000040.0005 (0,0010,013)
Service Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0011 (0,03)
Interference to Connecting Rod:
Press Fit Load (Normal Temp.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11013304 lbs. (5001500 kg)
742B, 743B Loader

8B3 Service Manual
Connecting Rod
Bend or Twist of Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0011 (0,03) or less
End Play of Big End . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.00390.010 (0,10,25)
Rod Bearing Oil Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.000550.0025 (0,0140,064)
Rod Bearing U.S. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.010 (0,25); 0.020 (0,50); 0.030 (0,75); 0.039 (1,0)
Crankshaft
Crankshaft Journal Oil Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.00060.0028 (0,0150,07)
Service Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.006 (0,15)
Crank Pin Oil Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.00040.0025 (0,010,064)
Service Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.004 (0,10)
Crankshaft Bearing U.S. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.010 (0,25); 0.020 (0,50); 0.030 (0,075)
Crankshaft Journal O.D. (Std.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.244 (57,0)
Service Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.035 (0,9)
Journal Undersize Machining Size:
0.010 (0,25) U.S. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.23372.2343 (56,73556,750)
0.020 (0,50) U.S. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.22382.2244 (56,48556,500)
0.030 (0,75) U.S. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.211402.2146 (56,23556,250)
Crank Pin O.D. (Std.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.772 (45,0)
Service Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.035 (0,9)
Pin Undersize Machining Size:
0.010 (0,25) U.S. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.76127.7618 (44,73444,750)
0.020 (0,50) U.S. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.75141.7520 (44,48544,500)
0.030 (0,75) U.S. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.74151.7421 (44,23444,250)
Bend of Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0012 (0,03) or less
Cylindrical Within Journal & Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0002 (0,005) or less
Crankshaft End Play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.00020.0069 (0,050,175)
Service Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.010 (0,25)
Flywheel
Flywheel RunOut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.005 (0,13) or less
Service Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.009 (0,2)
Camshaft
Journal O.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3386 (34,0)
Service Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.006 (0,15)
Cylindrical Within Journal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.00004 (0,001)
Service Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.006 (0,15)
Bend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0008 (0,02) or less
Height of Cam Lobe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4331 (36,4)
Service Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.020 (0,5)
Fuel Pump Drive Lobe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.575 (40,0)
Service Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.020 (0,5)
Camshaft End Play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.00020.0069 (0,050,175)
Service Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.012 (0,3)
Valve Train
Valve Stem O.D.:
Intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.315 (8,0)
Service Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.004 (0,10)
Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.315 (8,0)
Service Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.006 (0,15)
742B, 743B Loader

8B4 Service Manual
Valve Train (Contd)

Overall Length:
Intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.071 (103,4)
Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.937 (100)
Thickness of Head:
Intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.059 (1,5)
Service Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.020 (0,5)
Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.059 (1,5)
Service Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.020 (0,5)
Clearance to Guide:
Intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.00100.0023 (0,0250,058)
Service Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.004 (0,1)
Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.00200.0034 (0,050,085)
Service Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.006 (0,15)
Valve Clearance:
Cold
Intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.003 (0,08)
Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.007 (0,18)
Hot:
Intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.006 (0,15)
Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.010 (0,25)
Valve Guide
Valve Guide O.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.512 (13,0)
Valve Guide I.D.:
Intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.3150.317 (8,08,05)
Service Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.004 (0,10)
Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.3150.317 (8,08,05)
Service Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.006 (0,15)
Valve Guide Installed Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.5390.563 (13,714,3)
Valve Guide O.S. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.010 (0,05); 0.020 (0,25); 0.030 (0,50)
Valve Seat Ring O.S.:
Intake
0.012 (0,3) O.S. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.547 (39,3)
0.024 (0,6) O.S. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.559 (39,6)
Exhaust
0.012 (0,3) O.S. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.350 (34,3)
0.024 (0,6) O.S. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.362 (34,6)
Height of Ring:
0.012 (0,3) O.S. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.2910.299 (7,47,6)
0.024 (0,6) O.S. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.3030.311 (7,77,9)
Valve Spring
Color Code BLUE:
New Free Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.811 (46,0)
Service Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.039 (1,0)
New Preload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82 lbs. @ 1.469 (365 N @ 37,3)
Use Preload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 lbs. @ 1.106 (414 N @ 28,1)
Inclination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5
Service Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
742B, 743B Loader

8B5 Service Manual
Rocker Arm And Shaft

L.H. Rocker Shaft:
O.D. x Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.744 x 14.035 (18,9 x 356,5)
R.H. RockerShaft:
O.D. x Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.744 x 14.035 (18,9 x 350,5)
Bend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.020 (0,05) or less
Rocker Arm I.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.744 (18,9)
Arm to Shaft Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.00050.0017 (0,0120,043)
Rocker Shaft Spring:
Free Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.098 (53,3)
Preload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.7 lbs. @ 1.396 (16 N @ 35,5)
Oil Pump
Relief Valve Opening Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5771 lbs. (254316 N)
Outer to Inner Rotor Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.00160.004 (0,040,12)
Service Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.010 (0,25)
Pump Body to Outer Rotor Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.00390.006 (0,100,16)
Service Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.012 (0,3)
Rotor Side Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.00230.005 (0,060,12)
Service Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.008 (0,2)
Relief Spring:
Free Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.850 (47,0)
Preload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 lbs. @ 1.398 (71 N @ 35,5)
Fuel Pump
Delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.11 qts. (2 L) @ 5000 RPM
Closed Delivery Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.75 PSI (25,534,5 kPa)
Carburetor
Idle RPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 700750 RPM
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Downdraft
Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2832DIDSA
Main Jet Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.037 (0,94)
Main Air Jet Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.035 (0,9)
Pilot Jet Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.022 (0,55)
Pilot Air Jet Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.062 (1,6)
Enrichment Jet Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.023 (0,6)
Needle Valve Seat Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.078 (2,0)
Fast Idle Opening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Idle CompensatorFully Open Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131158F. (5570 C.)
Water Pump
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Centrifugal, Impeller Type
Belt Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.2760.394 @ 22 lbs. (710 @ 98 N)
Thermostat
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wax Type
Valve Cracking Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180 F. (82 C.)
Valve Lift & Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.31 (8,0) @ 203 F. (95 C.)
742B, 743B Loader

8B6 Service Manual
Starter
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Volt
Direction of Rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clockwise
Alternator
Output voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Amps. @ 2600 RPM
Distributor
Timing (With Vacuum Line Off) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 BTDC @ 700750 RPM
Direction of Rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clockwise
Ignition Firing Order . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1342
Centrifugal Spark Advance:
Beginning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 @ 1000 RPM
End . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 @ 2500 RPM
Vacuum Spark Advance:
Beginning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 @ 0.36 in. of mercury
Middle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 @ 9.84 in. of mercury
End . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 @ 15.8 in. of mercury
Point Gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0180.021 (0,440,55)
Dwell Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 + 3
Condenser Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 uF
Spark Plugs
Plug Gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0280.031 (0,70,8)
Engine Torque Ft.Lbs. Nm
Cylinder Head Bolts (Cold) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5154 6973

(Hot) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5861 7983
Rocker cover Mounting Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 5,46,8
Intake & Exhaust Manifold Mounting Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1114 1519
Camshaft Bearing Cap Mounting Bolts (M8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1415 1920
(M6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 9,512,2
Camshaft Sprocket Mounting Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3643 4958
Crankshaft Main Bearing Cap Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3640 4954
Connecting Rod Cap Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2325 3134
Crankshaft Pulley Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8094 113122
Flywheel Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5560 7581
Oil Pan Mounting Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 5,48,1
Oil Pan Drain Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3643 4958
Oil Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1116 1522
Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89 10,812,2
Oil Pump Sprocket Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2529 3440
Spark Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1822 2430
Alternator Support Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 9,512,2
Alternator Brace Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 9,512,2
Starter Mounting Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1623 2231
Crankshaft Pulley Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.58.5 10,211,5
Belt Tensioner Mounting Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1621 2228
Front Case Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1113 1518
Oil Screen Mounting Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1318 1824
Oil Pump Mounting Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1113 1518
Distributor Holding Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1521 2028
742B, 743B Loader

8B7 Service Manual
TECHNICAL DATA
Page
Number
DICIMAL AND MILLIMETER EQUIVALENTS
Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8C2
HYDRAULIC AND HYDROSTATIC FLUID SPECIFICATIONS
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8C1
STANDARD TORQUE SPECIFICATIONS FOR BOLTS

Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8C4
TORQUE FOR GENERAL METRIC BOLTS
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8C3
U.S. TO METRIC CONVERSION

Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8C2
TECHNICAL
DATA
742B, 743B Loader

8C1 Service Manual
HYDRAULIC/HYDROSTATIC FLUID SPECIFICATIONS
Use Melroe hydraulic/hydrostatic transmission fluid (P/N 6563328). If this fluid is not
available, use 10W30 or 10W40 SAE Motor Oil.
Use Class SE or SF motor oil (5W30 at temperatures below 10F (23C)).
DO NOT use automatic transmission fluids in this loader or permanent damage to

the transmission will result.
Where temperatures below zero are common, loaders must be kept in a warm
building. Extra warmup time must be used each time the loader is started during cold
temperature conditions. Cold fluid will not flow easily and it makes action of the
hydraulic function slower. Loss of fluid flow to the hydrostatic transmission pump
(indicated by TRANS light ON) will cause transmission damage in less than 60
seconds time.
When the temperature is below 20F (30C),

hydrostatic oil must be warmed before starting.
The hydrostatic system will not get enough oil
at low temperatures and will be damaged. Park
the machine in an area where the temperature
will be above 0F (18C) if possible.
I20071285
742B, 743B Loader

8C1 Service Manual
DECIMAL AND MILLIMETER EQUIVALENTS
FRACTIONS DECIMALS MM FRACTIONS DECIMALS MM

1/64 0.015625 0.397 33/64 0.515625 13.097
1/32 0.03125 0.794 17/32 0.53125 13.494
3/64 0.046875 1.191 35/64 0.546875 13.891
1/16 0.0625 1.588 9/16 0.5625 14.288
5/64 0.078125 1.984 37/64 0.578125 14.684
3/32 0.09375 2.381 19/32 0.59375 15.081
7/64 0.109375 2.778 39/64 0.609375 15.478
1/8 0.1250 3.175 5/8 0.6250 15.875
9/64 0.140625 3.572 41/64 0.640625 16.272
5/32 0.15625 3.969 21/32 0.65625 16.669
11/64 0.171875 4.366 43/64 0.671875 17.066
3/16 0.1876 4.762 11/16 0.6875 17.462
13/64 0.203125 5.159 45/64 0.703125 17.859
7/32 0.21875 5.556 23/32 0.71875 18.256
15/64 0.234375 5.953 47/64 0.734375 18.653
1/4 0.2500 6.350 3/4 0.7500 19.050
17/64 0.265625 6.747 49/64 0.765625 19.447
9/32 0.28125 7.144 25/32 0.78125 19.844
19/64 0.296875 7.541 51/64 0.796875 20.241
5/16 0.3125 7.938 13/16 0.8125 20.638
21/64 0.328125 8.334 53/64 0.828125 21.034
11/32 0.34375 8.731 27/32 0.84375 21.431
23/64 0.359375 9.128 55/64 0.859375 21.828
3/8 0.3750 9.525 7/8 0.8750 22.225
25/64 0.390625 9.922 57/64 0.890625 22.622
13/32 0.40625 10.319 29/32 0.90625 23.019
27/64 0.421875 10.716 59/64 0.921875 23.416
7/16 0.4375 11.112 15/16 0.9375 23.812
29/64 0.453125 11.509 61/64 0.953125 24.209
15/32 0.46875 11.906 31/32 0.96875 24.606
31/64 0.484375 12.303 63/64 0.984375 25.003
1/2 0.5000 12.700 1 1.000 25.400
1 mm = 0.03937 0.001 = 0.0254 mm
U.S. TO METRIC CONVERSION

TO CONVERT INTO MULTIPLY BY
LINEAR Miles Kilometers 1.609
MEASUREMENT Yards Meters 0.9144
Feet Meters 0.3048
Feet Centimeters 30.48
Inches Meters 0.0254
Inches Centimeters 2.54
Inches Millimeters 25.4
AREA Square Miles Square Kilometers 2.59
Square Feet Square Meters 0.0929
Square Inches Square Centimeters 6.452
Acre Hectare 0.4047
VOLUME Cubic Yards Cubic Meters 0.7646
Cubic Feet Cubic Meters 0.02832
Cubic Inches Cubic Centimeters 16.39
WEIGHT Tons (Short) Metric Tons 0.9078
Pounds Kilograms 0.4536
Ounces (Avdp.) Grams 28.3495
PRESSURE Pounds/Sq. In. Kilopascal 6.895
WORK FootPounds NewtonMeter 1.356
LIQUID VOLUME Quarts Liters 0.9463
Gallons Liters 3.785
LIQUID FLOW Gallons/Minute Liters/Minute 3.785
TEMPERATURE Fahrenheit Celsius 1.Subtract 32
2. Multiply by 5/9
742B, 743B Loader
8C2 Service Manual
TORQUE FOR GENERAL METRIC BOLTS
Material
Thread Size
(Dia. x Pitch) Head Mark 4 Head Mark 7 Head Mark 10
M 5 x 0,8 34 ft.lbs.
(45 Nm)
M 6 x 1,0 67 ft.lbs. 69 ft.lbs.
(89 Nm) (812 Nm)
M 8 x 1,25 66 ft.lbs. 1116 ft.lbs. 1825 ft.lbs.
(812 Nm) (1522 Nm) (2434 Nm)
(1824 Nm) (3041 Nm) 4968 Nm)
(3041 Nm) (5473 Nm) (94118 Nm)
(4968 Nm) (79108 Nm) (157186 Nm)
742B, 743B Loader

8C3 Service Manual
STANDARD TORQUE SPECIFICATIONS FOR BOLTS
742B(S/N509418001&Above),743B(S/N509318001&Above)ServiceManual#6720772SpecificationsSectionPart3of3
The following table shows standard torque specifications for bolts with zinc
phosphate coating. Bolts purchased from Melroe that have zinc phosphate coating
are specified by the letter H following the part number.
THREAD
SIZE SAE GRADE 5 SAE GRADE 8
INCH. .250 8090 110120

LBS. (9,010,2) (12,413,6)
(Nm)
.3125 180200 215240
(20,322,6) 24,227,1)
.375 2528 3540
(3438) (4754)
.4375 4045 6065
(5461) (8188)
.500 6570 90100
(8895) (122136)
.5625 90100 125140
(122136) (170190)
.625 125140 175190
(170190) (240260)
FOOT .750 220245 300330
LBS. (300330) (410450)
(Nm)
.875 330360 475525
(450490) (645710)
1.000 475525 725800
(645710) (9851085)
1.125 650720 10501175
(880975) (14251600)
1.250 9001000 14751625
(12001360) (20002200)
1.375 12001350 20002200
(16301830) (27202980)
1.500 15001650 26002850
(20402240) (35303870)
1.625 20002800 34503800
(27202980) (46805150)
1.750 25002750 43004800
(33903730) (58306500)
1.875 31503500 55006100
(42704750) (74508300)
2.000 38004200 65007200
(51505700) (88009800)
742B, 743B Loader

8C4 Service Manual
742B, 743B001
Revision Number
28 January 1993
SERVICE MANUAL Date
REVISION ROUTE TO
ATTENTION
AFFECTING:
PARTS MANAGER
Product BOBCAT LOADER
SERVICE MANAGER X
Model 742B & 743B (S/N 18001 & Above) SALES MANAGER
Manual No. 6720772 (792)
NOTICE Insert This Sheet With The Appropriate Manual For Future Reference.
The following pages are a revision to the 742B & 743B (S/N 18001 & Above) Service Manual P/N 6720772 (792).
Take out and put in the revised pages as listed below:
TAKE OUT PUT IN
11, 12 11 (Revised Jan. 93), 12
HYDRAULIC/HYDROSTATIC FLOW CHART HYDRAULIC/HYDROSTATIC FLOW CHART
For Model For Model
742B & 743B (S/N 18001 & Above) 742B & 743B (S/N 18001 & Above)
Chart #6722239 (Printed July 1992) Chart #6722239 (Printed January 1993)
HYDRAULIC/HYDROSTATIC SYSTEM OPERATION HYDRAULIC/HYDROSTATIC SYSTEM OPERATION
To Be Used With To Be Used With
Chart #6722239 (Printed July 1992) Chart #6722239 (Printed January 1993)
742B, 743B002
Revision Number
22 September 1993
SERVICE MANUAL Date
REVISION ROUTE TO
ATTENTION
AFFECTING:
PARTS MANAGER
SERVICE MANAGER X
Manual No. 6720772 (792)
TAKE OUT PUT IN
Maintenance Safety Page Maintenance Safety Page
11, 12 11 (Revised Sept. 93), 12
113, 114 113 (Revised Sept. 93), 114
Section 4 Content Page Section 4 Content Page (Revised Sept. 93)
41 thru 418 41 thru 418 (Revised Sept. 93)
419 (Added Sept. 93)
Section 6 Content Page Section 6 Content Page (Revised Sept. 93)
CAB WIRING DIAGRAM (P/N 6722266) CAB WIRING DIAGRAM (P/N 6722266)
Model 742B & 743B (S/N 18001 & Above) Model 742B & 743B (S/N 18001 & Above)
(Printed July 1992) (Printed September 1993)
ENINE WIRING DIAGRAM (P/N 6722240) ENGINE WIRING DIAGRAM (P/N 6722240)
Model 742B & 743B (S/N 18001 & Above) Model 742B & 743B (S/N 18001 & Above)
(Printed July 1992) (Printed September 1993)
63 thru 615 63 thru 615 (Revised Sept. 93)
616 thru 620 (Added Sept. 93)
7A1, 7A2 7A1, 7A2 (Revised Sept. 93)
7A9, 7A10 7A9 (Revised Sept. 93), 7A10
8A1, 8A2 8A1 (Revised Sept. 93), 8A2
8B1, 8B2 8B1 (Revised Sept. 93), 8B2
742B, 743B003
Revision Number
3 May 1996
SERVICE MANUAL Date
REVISION ROUTE TO
ATTENTION
AFFECTING:
PARTS MANAGER
SERVICE MANAGER X
Manual No. 6720772 (792)
TAKE OUT PUT IN
15, 16 15 (Revised May 96), 16 (Revised May 96)
211, 212 211, 212 (Revised May 96)
213, 214 213 (Revised May 96), 214
742B, 743B004
Revision Number
12 July 1996
SERVICE MANUAL Date
REVISION ROUTE TO
ATTENTION
AFFECTING:
PARTS MANAGER
SERVICE MANAGER X
Manual No. 6720772 (792)
TAKE OUT PUT IN
121, 122 121 (Revised July 96), 122
HYDROSTATIC SYSTEM TAB PAGE HYDROSTATIC SYSTEM TAB PAGE (Revised July 96)
37, 38 37 (Revised July 96), 38 (Revised July 96)
317 317 (Revised July 96), 318 (Added July 96)
ENGINE SERVICE TAB PAGE ENGINE SERVICE TAB PAGE (Revised July 96)
(Kubota 743B) (Kubota 743B)
7A3, 7A4 7A3 (Revised July 96), 7A4
7B11, 7B12 7B11, 7B12 (Revised July 96)

Bobcat 742b y 743b

Încărcat de

Informații document

Drepturi de autor

Formate disponibile

Partajați acest document

Partajați sau inserați document

Opțiuni de partajare

Vi se pare util acest document?

Este necorespunzător acest conținut?

Drepturi de autor:

Formate disponibile

Bobcat 742b y 743b

Încărcat de

Drepturi de autor:

Formate disponibile

7

CORRECT CORRECT CORRECT

B-10731a B-12365 B-7469

B-11799 B-15231 B-15280

B-6590 B-6580 B-6589

742B, 743B Loader

1. Check that the ROPS/FOPS 9. Enclosure door latches must

2. Check that ROPS mounting 10. BobTach wedges and

5. Machine signs must be legible 13. Check hydraulic fluid level,

7. Check for correct function of 15. Lubricate the loader.

8. The parking brake must 16. Check the condition of the

742B, 743B Loader

18. Check the electrical charging

19. Check tires for wear and

20. Inspect for loose or broken

21. Operate the loader and check

22. Check for any field

23. Check for correct function of

Recommend to the owner that all

742B, 743B Loader

Warnings on the machine and in the This notice identifies procedures

742B, 743B Loader

742B, 743B Loader

ENGINE SERIAL NUMBER (743B) P00208

The serial number is located at the fuel injection pump

The serial number is located at top left surface of the

The Delivery Report must be filled out by the dealer and

742B, 743B Loader

BUCKET SAFETY TREAD

742B, 743B Loader

ALTERNATOR BELT ADJUSTMENT (743B)

ENGINE COOLING SYSTEM (743B)

ENGINE COOLING SYSTEM (742B)

ENGINE LUBRICATION SYSTEM (743B)

ENGINE LUBRICATION SYSTEM (742B)

FUEL SYSTEM (743B)

FUEL SYSTEM (742B)

742B, 743B Loader

LIFTING AND BLOCKING THE LOADER

LUBRICATING THE BOBCAT LOADER

REMOTE START SWITCH

SEAT BAR RESTRAINT SYSTEM

SPARK ARRESTOR MUFFLER

USING A BOOSTER BATTERY (Jump Starting)

742B, 743B Loader

Instructions are necessary before operating or servicing machine. Read

SERVICE SCHEDULE HOURS

ITEM SERVICE REQUIRED 810 50 100 250 500 1000

Instructions are necessary before operating or

LIFTING AND BLOCKING THE LOADER

Put jackstands under the front axles and rear

NOTE: Make sure the jackstands do not touch the

742B, 743B Loader

AVOID INJURY OR DEATH

Engage the parking brake.

TRANSPORTING THE BOBCAT LOADER

Adequately designed ramps of sufficient

A loader with an empty bucket or no attachment must be B07383

742B, 743B Loader

Never work on a machine with the lift arms up

To Disengage Lift Arm Support Device

742B, 743B Loader

FOPS) as standard equipment to protect the operator Bushing

Never modify operator cab by welding,